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Mitsubishi LANCER EVOLUTION-IV 1998 Workshop Manual Download Page 341

MANUAL TRANSMISSION OVERHAUL – 

Output Shaft

22B-31

"

G

A

2ND SPEED GEAR SLEEVE INSTALLATION

"

H

A

3RD SPEED GEAR INSTALLATION

"

I

A

SNAP RING INSTALLATION

Select and install a snap ring so that the output shaft 3rd
speed gear clearance will have the standard value.

Standard value: 0 – 0.09 mm

"

J

A

4TH SPEED GEAR INSTALLATION

"

K

A

5TH SPEED GEAR SLEEVE INSTALLATION

2nd speed 
gear sleeve

MD998364

MD998824

MD998812

MD998814

3rd speed gear

MD998364

MD998824

MD998812

MD998814

Snap ring

4th speed
gear

MD998364

MD998812

MD998813

MD998821

5th speed 
gear sleeve

MD998364

MD998812

MD998813

MD998821

Summary of Contents for LANCER EVOLUTION-IV 1998

Page 1: ...Pub No S9806CNCP9 WORKSHOP MANUAL EVOLUTION IV EVOLUTION V Pub No S9806CNCP9 Pub No S9806CNCP9 Jul 98 Printed in Japan WORKSHOP MANUAL EVOLUTION IV EVOLUTION V...

Page 2: ...tains procedures for service mechanics including removal disassembly inspection adjustment reassembly and installation Figures taken from registration documents are given in metric units only All othe...

Page 3: ...HOW TO READ THE WIRING DIAGRAMS A ELECTRICAL WIRING EVOLUTION IV B ELECTRICAL WIRING EVOLUTION V C ELECTRICAL WIRING CONTENTS...

Page 4: ...NOTES...

Page 5: ...D LIGHTING MONITOR ALARM BUZZER 40 FOG LAMP 42 ROOM LAMP AND LUGGAGE COMPARTMENT LAMP 43 TURN SIGNAL LAMP AND HAZARD LAMP 44 STOP LAMP 47 BACK UP LAMP 48 HORN VEHICLES WITHOUT SRS AIR BAG 49 OIL PRESS...

Page 6: ...nator A 09 1 B Starter A 10 1 Starter A 12 2 B Fuel pressure solenoid valve A 16 4 B Throttle position sensor A 18 6 B Idle speed control servo A 19 3 B Vehicle speed sensor A 20 4 B Windshield wiper...

Page 7: ...A 33 1 Horn LH A 34 1 Horn LH A 35 2 BR Outside air temperature sensor vehicles with fully automatic air conditioner A 38 2 B Engine coolant temperature sensor A 39 1 B Engine coolant temperature gaug...

Page 8: ...Engine speed detection connector A 74 1 B Fuel pump check connector A 76 6 Valve relay vehicles with ABS A 77 5 Motor relay vehicles with ABS A 78 2 GR Side turn signal lamp LH A 80X 5 Horn relay veh...

Page 9: ...2 BR Front turn signal lamp RH A 110 3 GR Ignition coil 1 A 111 3 GR Ignition coil 2 A 112X 4 Radiator fan relay HI A 113X 4 Condenser fan relay LO A 114X 4 Condenser fan relay HI A 116X 4 A C compre...

Page 10: ...ECU vehicles with fully automatic air conditioner B 06 6 Air outlet change over damper motor and potentiometer vehicles with fully automatic air conditioner B 07 8 Blower switch vehicles with manual...

Page 11: ...B 30 14 Radio or spare connector for radio B 31 1 Glass antenna amplifier B 32 19 B Jumper connector 5 B 33 2 Blower motor vehicles with fully automatic air conditioner B 34 4 Blower high speed relay...

Page 12: ...r conditioner B 41 8 A C switch vehicles with manual air conditioner B 42 2 Blower switch illumination lamp vehicles with heater or manual air conditioner B 43 6 B Defogger switch vehicles with heater...

Page 13: ...B 59 26 Y Engine ECU B 60 16 Y Engine ECU B 61 12 Y Engine ECU B 62 22 Y Engine ECU B 63 2 Blower motor vehicles with heater or manual air conditioner B 64 13 Control harness and body harness combina...

Page 14: ...10 Junction block and body harness combination B 75 10 B Junction block and body harness combination B 76 8 Junction block and body harness combination B 77 8 ETACS ECU B 78 4 Junction block and body...

Page 15: ...B 11 NOTES...

Page 16: ...05 6 Body harness and rear door harness RH combination D 06 22 Body harness and rear harness combina tion D 07 6 Sunroof switch D 08 8 Room lamp vehicles with sunroof D 09 1 Map lamp D 10 18 Sunroof...

Page 17: ...les with ABS or AYC D 21 1 B Parking brake switch D 22 2 B High temperature sensor D 23 Reclining motor D 24 Slide limit switch D 25 2 Body harness and power seat harness combination and power seat sw...

Page 18: ...iper motor F 12 1 B Rear door switch RH F 13 2 Highmounted stop lamp installed onrear spoiler F 15 6 Rear combination lamp RH F 16 2 GR Licence plate lamp RH F 17 1 B Luggage compartment lamp switch F...

Page 19: ...B 15 NOTES...

Page 20: ...fan motor relay HI B Fuel pump relay No 2 AYC relay C Radiator fan motor relay LO B 16 SINGLE PART INSTALLATION POSITION RELAY Name Symbol Name Symbol AYC relay B Fuel pump relay No 2 B Condenser fan...

Page 21: ...SINGLE PART INSTALLATION POSITION ECU A B 17 ECU Name Symbol AYC ECU A...

Page 22: ...ensor lateral vehicles with AYC I Knock sensor B Acceleration sensor longitudinal vehicles with ABS and AYC I Outside air temperature sensor vehicles with fully automatic air conditioner F Air flow se...

Page 23: ...ATION POSITION Sensor E O2 sensor F Outside air temperature sensor G Engine coolant temperature sensor Camshaft position sensor H Steering angle sensor I Acceleration sensor longitudinal Acceleration...

Page 24: ...solenoid valve C Waste gate solenoid valve D Rear combination lamp RH Direction valve Proportioning valve B 20 SOLENOID VALVE Name Symbol Name Symbol Direction valve vehicles with AYC D Secondary air...

Page 25: ...Connector SINGLE PART INSTALLATION POSITION A Engine speed check connector Fuel pump check connector B 21 CHECK CONNECTOR AND SPARE CONNECTOR Name Symbol Name Symbol Engine speed check connector A Fu...

Page 26: ...le Link and Fuse Ground Cable SINGLE PART INSTALLATION POSITION B 22 FUSIBLE LINK AND FUSE Vehicles with AYC vehicles without ABS Fusible link Vehicles with AYC vehicles with ABS Fusible link GROUND C...

Page 27: ...SINGLE PART INSTALLATION POSITION Ground 1 2 5 6 B 23 GROUND 1 2 5 6 7 14 15 13 11 12 10 9...

Page 28: ...SINGLE PART INSTALLATION POSITION Ground 7 9 10 11 12 11 12 13 14 15 B 24...

Page 29: ...tive yaw control system Screw in type Yellow 60 Fuse box directly attached on battery Vehicles with AYC W R R R B CENTRALIZED RELAY Connector No Name Connector No Name A 82X Radiator fan motor relay L...

Page 30: ...SYSTEM ACTIVE YAW CONTROL SYSTEM DEDICATED FUSE RELAY BOX IN ENGINE COMPARTMENT HEATER AND MANUAL AIR CONDITIONER FULLY AUTOMATIC AIR CONDITIONER COOLING SYSTEM DEDICATED FUSE A C RELAY BOX IN ENGINE...

Page 31: ...ACTIVE YAW CONTROL SYSTEM ANTILOCK BRAKE SYSTEM STOP LAMP CLOCK AND MULTI DISPLAY SUNROOF CIGARETTE LIGHTER AND ASHTRAY ILLUMINATION LAMP METER AND GAUGE TURN SIGNAL LAMP AND HAZARD LAMP TAIL LAMP PO...

Page 32: ...R AND GAUGE CHARGING SYSTEM CENTRAL DOOR LOCKING SYSTEM TAIL LAMP POSITION LAMP LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER FUEL WARNING LAMP FOOT LAMP BRAKE WARNING LAMP RADIO SPARE CONNECTOR FOR...

Page 33: ...REMOTE CONTROLLED DOOR MIRROR ELECTRICALLY REMOTE CONTROLLED DOOR MIRROR CLOCK AND MULTI DISPLAY CENTRAL DOOR LOCKING SYSTEM VEHICLES WITH KEYLESS ENTRY SYSTEM RADIO SPARE CONNEC TOR FOR RADIO MULTI...

Page 34: ...M IGNITION KEY CYLINDER ILLUMINATION LAMP IGNITION KEY REMINDER BUZZER ENGINE CONTROL SYSTEM CLOCK AND MULTI DISPLAY METER AND GAUGE CENTRAL DOOR LOCKING SYSTEM TAIL LAMP POSITION LAMP LICENCE PLATE L...

Page 35: ...CIRCUIT DIAGRAM Starting System BATTERY IGNITION SWITCH ST ENGINE CONTROL SYSTEM STARTER B 31 STARTING SYSTEM...

Page 36: ...2 NOISE CON DENSER INPUT SIGNAL IDLE SWITCH IGNITION SWITCH ST CAM POSITION SENSOR INTAKE AIR TEMPERATURE SENSOR CRANK ANGLE SENSOR VEHICLE SPEED SENSOR ENGINE COOLANT TEMPERATURE SENSOR BAROMETRIC P...

Page 37: ...E LINK IGNITION SWITCH IG1 TAIL LAMP POSITION LAMP LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER POWER SUPPLY FOG LAMP HEADLAMP ENGINE ECU ALTERNATOR RELAY COMBINATION METER STATOR COIL FIELD COIL AL...

Page 38: ...l System FUSIBLE LINK FUSIBLE LINK IGNITION SWITCH IG1 VACANT TERMINAL COMBINATION METER ENGINE CONTROL RELAY ACTIVE YAW CONTROLSYSTEM ANTI LOCK BRAKE SYSTEM ENGINE ECU POWER SUPPLY BACK UP POWER SUPP...

Page 39: ...CIRCUIT DIAGRAM Engine Control System FUEL PUMP RELAY FUEL PUMP RESISTOR FUEL PUMP RELAY NO 2 FUEL PUMP FUEL PUMP INSPECTION CONNECTOR IGNITION SYSTEM B 35...

Page 40: ...Engine Control System ENGINE CONTROL RELAY CAMSHAFT POSITION SENSOR CRANK ANGLE SENSOR IDLESPEED CONTROL SERVO ENGINE ECU O2 SENSOR IDLE SWITCH THROTTLE POSITION SENSOR FRONT VIEW B 36 ENGINE CONTROL...

Page 41: ...ngine Control System RESISTOR FOR INJECTOR INJECTOR MULTI PURPOSE FUSE CENTRAL DOOR LOCKING SYSTEM VEHICLES WITH KEYLESS ENTRY SYSTEM FULLY AUTOMATIC AIR CONDITIONER DIAGNOSIS CONNECTOR INJECTOR INJEC...

Page 42: ...NE ECU ENGINE COOLANT TEMPERATURE SENSOR AIR FLOW SENSOR INTAKE AIR TEMPERATURE SENSOR BAROMETRIC PRES SURE SENSOR ENGINE ECU METER AND GAUGE RADIO KNOCK SENSOR VEHICLE SPEED SENSOR POWERSTEERINGOIL P...

Page 43: ...ROL SERVO IGNITION SWITCH ST FUEL PRESSURE SOLENOID VALVE WASTE GATE SOLENOID VALVE SECONDARY AIR CONTROL SOLENOID VALVE STARTING SYSTEM AIR CONDITIONER COOLING SYSTEM IGNITION SYSTEM METER AND GAUGE...

Page 44: ...SWITCH IG2 RADIATOR FAN MOTOR RELAY HI RADIATOR FAN MOTOR RELAY LO RADIATOR FAN MOTOR INPUT SIGNAL A C SWITCH IDLE SWITCH CRANK ANGLE SENSOR VEHICLE SPEED SENSOR ENGINE COOLANT TEMPERATURE SENSOR THR...

Page 45: ...DITIONER FULLY AUTOMATIC AIR CONDITIONER CONDENSER FAN MOTOR RELAY HI DEDICATED FUSE CONDENSER FAN MOTOR RELAY LO CONDENSER FAN MOTOR HEATER AND MANUAL AIR CONDITIONER FULLY AUTOMATIC AIR CONDITIONER...

Page 46: ...sition Lamp License Plate Lamp and Lighting Monitor Alarm Buzzer COLUMN SWITCH TAIL LAMP LH REAR COMBINATION LAMP TAIL LAMP RH LICENSE PLATE LAMP B 42 TAIL LAMP POSITION LAMP LICENSE PLATE LAMP AND LI...

Page 47: ...COLUMN SWITCH TAIL LAMP LH REAR COMBINATION LAMP TAIL LAMP RH LICENSE PLATE LAMP CIRCUIT DIAGRAM Tail Lamp Position Lamp License Plate Lamp and Lighting Monitor Alarm Buzzer B 43...

Page 48: ...POWER SUPPLY HEADLAMP DEDICATED FUSE COLUMN SWITCH LIGHTING SWITCH FOG LAMP SWITCH FOG LAMP CLOCK MULTI DISPLAY CIGARETTE LIGHTER ASH TRAY ILLUMINATION LAMP TURNSIGNAL LAMP HAZARD WARNING LAMP ELECTR...

Page 49: ...MP ROOM LAMP ROOM LAMP COMBINATION METER MAP LAMP DEFOGGER VEHICLES WITHOUT KEYLESS ENTRY SYSTEM VEHICLESWITH KEYLESS ENTRY SYSTEM DIODE LUGGAGE COMPARTMENT LAMP CENTRAL DOOR LOCKING SYSTEM VEHICLES W...

Page 50: ...M HEADLAMP DEDICATED FUSE FOG LAMP COLUMN SWITCH LIGHTING SWITCH HAZARD SWITCH DEDICATED FUSE NOTE CLOCK AND MULTI DISPLAY CIGARETTE LIGHTER AND ASHTRAY ILLUMINATION LAMP ELECTRIC RETRACTABLE REMOTE C...

Page 51: ...CIRCUIT DIAGRAM Turn signal Lamp and Hazard Lamp TURN SIGNAL AND HAZARD FLASHER UNIT HAZARD SWITCH SIDE TURN SIGNAL LAMP FRONT TURN SIGNALLAMP SIDE TURN SIGNAL LAMP B 47...

Page 52: ...p and Hazard Lamp HAZARDSWITCH TURN SIGNAL AND HAZARD FLASHER UNIT REAR COMBINATION LAMP TURN RH REAR COMBINATION LAMP TURN LH COLUMN SWITCH TURN SIGNAL LAMP SWITCH COMBINATION METER B 48 TURN SIGNAL...

Page 53: ...DEDICATED FUSE STOP LAMP SWITCH ANTI LOCK BRAKE SYSTEM INSTALLED ON REAR SPOILER INSTALLED ON REAR SHELF REAR COMBINATION LAMP STOP RH STOP LH HIGH MOUNTED STOP LAMP VACANT CONNECTOR SOME MODELS HIGH...

Page 54: ...CIRCUIT DIAGRAM Back up Lamp IGNITION SWITCH IG1 BACK UP LAMP SWITCH REAR COMBINATION LAMP BACK UP LH REAR COMBINATION LAMP BACK UP RH B 50 BACK UP LAMP...

Page 55: ...IT DIAGRAM Horn Vehicles without SRS Air Bag IGNITION SWITCH ACC DEDICATED FUSE HORN RH HORN LH DUAL HORN ONLY COLUMN SWITCH HORN SWITCH VACANT CONNECTOR SOME MODELS B 51 HORN VEHICLES WITHOUT SRS AIR...

Page 56: ...CIRCUIT DIAGRAM Oil Pressure Warning Lamp IGNITION SWITCH IG1 COMBINATION METER OIL PRESSURE SWITCH CHARGING SYSTEM B 52 OIL PRESSURE WARNING LAMP...

Page 57: ...B 53 NOTES...

Page 58: ...ntral Door Locking System Vehicles with Keyless Entry System FUSIBLE LINK IGNITION SWITCH IG1 RECEIVER KEY REMINDER SWITCH DOOR LOCK ACTUATOR FRONT RH B 54 CENTRAL DOOR LOCKING SYSTEM VEHICLES WITH KE...

Page 59: ...CIRCUIT DIAGRAM Central Door Locking System Vehicles with Keyless Entry System DOOR LOCK ACTUATOR FRONT LH DOOR LOCK ACTUATOR REAR RH DOOR LOCK ACTUATOR REAR LH B 55...

Page 60: ...tem MULTI PURPOSE FUSE VEHICLES WITHOUT SUNROOF VEHICLES WITH SUNROOF ROOM LAMP VEHICLESWITH MAP LAMP ROOM LAMP MAPLAMP COMBINATION METER DIODE FRONT DOOR SWITCH REAR DOOR SWITCH FRONT VIEW SUNROOF B...

Page 61: ...cking System Vehicles with Keyless Entry System IGNITION SWITCH ACC RECEIVER RADIO RECEIVING ANTENNA ANTI LOCK BRAKE SYSTEM ENGINE CONTROL SYSTEM FULLY AUTOMATIC AIR CONDITIONER CONTROL CIRCUIT TRANSM...

Page 62: ...ditioner FUSIBLE LINK CHARGING SYSTEM POWER SUPPLY HEADLAMP DEDICATED FUSE FOG LAMP COLUMN SWITCH LIGHTING SWITCH FUSIBLE LINK IGNITION SWITCH IG2 BLOWER MOTOR RELAY BLOWER MOTOR RESISTOR BLOWER SWITC...

Page 63: ...CIRCUIT DIAGRAM Heater and Manual Air Conditioner COLUMN SWITCH BLOWER SWITCH HEATER CONTROL PANEL ILLUMINATION LAMP A C SWITCH BLOWER SWITCH AUTOMATIC COMPRESSOR ECU B 59...

Page 64: ...CH IG2 RADIATOR FAN MOTOR RELAY HI RADIATOR FAN MOTOR RELAY LO RADIATOR FAN MOTOR INPUT SIGNAL A C SWITCH IDLE SWITCH CRANK ANGLE SENSOR VEHICLE SPEED SENSOR ENGINE COOLANT TEMPERATURE SENSOR THROTTLE...

Page 65: ...CIRCUIT DIAGRAM Heater and Manual Air Conditioner FUSIBLE LINK DEDICATED FUSE CONDENSER FAN MOTOR RELAY HI DEDICATED FUSE CONDENSER FAN MOTOR RELAY LO CONDENSER FAN MOTOR AUTOMATIC COMPRESSOR ECU B 61...

Page 66: ...ir Conditioner AUTOMATIC COMPRESSOR ECU FUSIBLE LINK DUAL PRESSURE SWITCH DEDICATED FUSE A C COMPRESSOR RELAY ENGINE ECU REFRIGERANT TEMPERATURE SWITCH A C COMPRESSOR AND MAGNETIC CLUTCH B 62 HEATER A...

Page 67: ...B 63 NOTES...

Page 68: ...y Automatic Air Conditioner FUSIBLE LINK IGNITION SWITCH IG2 BLOWER MOTOR RELAY BLOWER MOTOR BLOWER HIGH SPEED RELAY BACK UP POWER SUPPLY POWER TRAN SISTOR DRIVE CIRCUIT POWER SUPPLY B 64 FULLY AUTOMA...

Page 69: ...Conditioner FUSIBLE LINK CHARGING SYSTEM POWER SUPPLY HEADLAMP DEDICATED FUSE POWER TRANSISTOR BLOWER MOTOR BLOWERHIGH SPEED RELAY FOG LAMP COLUMN SWITCH LIGHTING SWITCH POWER TRAN SISTOR DRIVE CIRCUI...

Page 70: ...ER POTENTIOMETER AIR THERMO SENSOR HEATER WATER TEMPERATURE SENSOR DEDICATED IC AIR OUTLET CHANGEOVER DAMPER MOTOR AIR MIX DAMPER MOTOR INSIDE AND OUTSIDE AIR CHANGEOVER DAMPER MOTOR DEDICATED IC DEDI...

Page 71: ...ic Air Conditioner OUTSIDEAIR TEMPERATURE SENSOR SUNLIGHT SENSOR DEFOGGER ANTI LOCK BRAKE SYSTEM ENGINE CON TROL SYSTEM CENTRAL DOOR LOCK ING SYSTEM VEHICLES WITH KEYLESS ENTRY SYS TEM DIAGNOSIS CONNE...

Page 72: ...CH IG2 RADIATOR FAN MOTOR RELAY HI RADIATOR FAN MOTOR RELAY LO RADIATOR FAN MOTOR INPUT SIGNAL A C SWITCH IDLE SWITCH CRANK ANGLE SENSOR VEHICLE SPEED SENSOR ENGINE COOLANT TEMPERATURE SENSOR THROTTLE...

Page 73: ...CIRCUIT DIAGRAM Fully Automatic Air Conditioner FUSIBLE LINK DEDICATED FUSE CONDENSER FAN MOTOR RELAY HI DEDICATED FUSE CONDENSER FAN MOTOR RELAY LO CONDENSER FAN MOTOR B 69...

Page 74: ...Automatic Air Conditioner DUAL PRESSURE SWITCH DEDICATED FUSE DEDICATED FUSE A C COMPRESSOR RELAY REFRIGERANT TEMPERATURESWITCH A CCOMPRESSOR AND MAGNETIC CLUTCH ENGINE ECU B 70 FULLY AUTOMATIC AIR C...

Page 75: ...B 71 NOTES...

Page 76: ...WIPER RELAY IGNITION SWITCH ACC IN CASE OF OPERATION INTERVAL FIXED TYPE INTERMITTENT WIPER VARIABLE INTER MITTENT WIPER CONTROL SWITCH WINDSHIELD WASHER SWITCH WINDSHIELD WIPER SWITCH WASHER MOTOR WI...

Page 77: ...CIRCUIT DIAGRAM Rear Wiper and Washer IGNITIONSWITCH ACC WINDSHIELDWIPER AND WASHER COLUMN SWITCH REAR INTERMITTENT WIPER RELAY WASHER MOTOR REAR WIPER MOTOR B 73 REAR WIPER AND WASHER...

Page 78: ...CHARGING SYSTEM POWERSUPPLY HEADLAMP DEDI CATED FUSE FOG LAMP COLUMN SWITCH LIGHT ING SWITCH DEFOGGER SWITCH IGNITIONSWITCH IG2 FUSIBLE LINK DEFOGGER RELAY VEHICLES WITHOUT GLASS ANTENNA VEHICLES WITH...

Page 79: ...ter Vehicles without Fully Automatic Air Conditioner PRINTED HEATER WIRE DOOR MIRROR PRINTED HEATER WIRE DEFOGGER RELAY ROOM LAMP AND LUGGAGE COMPARTMENT LAMP VEHICLES WITH GLASS ANTENNA VEHICLES WITH...

Page 80: ...er Vehicles with Fully Automatic Air Conditioner IGNITIONSWITCH IG2 FUSIBLE LINK DEFOGGER RELAY VEHICLESWITHOUT GLASS ANTENNA VEHICLES WITH GLASS ANTENNA DEFOGGER B 76 DEFOGGER AND DOOR MIRROR HEATER...

Page 81: ...eater Vehicles with Fully Automatic Air Conditioner PRINTED HEATER WIRE DOOR MIRROR PRINTED HEATER WIRE DEFOGGER RELAY ROOM LAMP AND LUGGAGE COMPARTMENT LAMP VEHICLES WITH GLASS ANTENNA CHOKE COIL VEH...

Page 82: ...STEM POWER SUPPLY HEADLAMP DEDICATED FUSE FOG LAMP COLUMN SWITCH LIGHTING SWITCH SPARE CONNECTOR FOR RADIO IGNITION SWITCH ACC CENTRAL DOOR LOCKING SYSTEM VEHICLES WITH KEYLESS ENTRY SYSTEM FUSIBLELIN...

Page 83: ...NNA ANTENNA FEEDER LINE VEHICLES WITH GLASS ANTENNA REAR WINDOW GLASS ANTENNA GLASS ANTENNA AMPLIFIER ANTENNA FEEDER LINE METER AND GAUGE SPARECONNECTORFOR DOOR SPEAKER IGNITIONSWITCH IG1 SUNROOF SEAT...

Page 84: ...YSTEM POWER SUPPLY HEADLAMP DEDICATED FUSE FOG LAMP COLUMN SWITCH LIGHTING SWITCH CENTRAL DOOR LOCK ING SYSTEM VEHICLES WITH KEYLESS ENTRY SYS TEM VEHICLESWITH POLE ANTENNA POLEANTENNA ANTENNA FEEDER...

Page 85: ...ICLES WITH GLASS DIVERSITY ANTENNA REAR WINDOW GLASS ANTENNA GLASS ANTENNA AMPLIFIER ANTENNA FEEDER LINE DOOR SPEAKER LH DOOR SPEAKER RH TWEETER RH VEHICLES WITH 6 SPEAKERS IGNITION SWITCH IG1 ENGINE...

Page 86: ...CIRCUIT DIAGRAM Anti lock Brake System ABS BATTERY FUSIBLE LINK DEDICATED FUSE STOP LAMP SWITCH STOP LAMP ENGINE CONTROL SYSTEM BACK UP POWER SUPPLY B 82 ANTI LOCK BRAKE SYSTEM ABS...

Page 87: ...CIRCUIT DIAGRAM Anti lock Brake System ABS IGNITION SWITCH IG2 ACTIVE YAW CONTROL SYSTEM INTERCOOLER WATER SPRAY SYSTEM VEHICLES WITHOUT AYC VEHICLES WITH AYC B 83...

Page 88: ...IT DIAGRAM Anti lock Brake System ABS IGNITION SWITCH IG1 FUSIBLE LINK MULTI PURPOSE FUSE COMBINATION METER VALVE RELAY MOTOR RELAY DIODE ACTIVE YAW CONTROL SYSTEM B 84 ANTI LOCK BRAKE SYSTEM ABS CONT...

Page 89: ...Anti lock Brake System ABS ACTIVE YAW CONTROL SYSTEM FRONT SPEED SENSOR REAR SPEED SENSOR ACCELERATION SENSOR LONGITUDINAL NOISE FILTER AMPLI FYING CIRCUIT LOW PASS FILTER TRANSFORMER CIRCUIT DETEC TI...

Page 90: ...AULIC UNIT INLET VALVE FRONT LH FRONT RH REAR LH REAR RH OUTLET VALVE FRONT LH FRONT RH REAR LH REAR RH CENTRAL DOOR LOCKING SYSTEM VEHICLES WITH KEYLESS ENTRY SYSTEM FULLY AUTOMATIC AIR CONDITIONER D...

Page 91: ...B 87 NOTES...

Page 92: ...stem AYC FUSIBLE LINK IGNITION SWITCH IG2 INTERCOOLER WATER SPRAY SYSTEM ACCELERA TION SENSOR LATERAL ACCEL ERATION SENSOR LONGITU DINAL ENGINE CONTROL SYSTEM ANTI LOCK BRAKE SYSTEM BACK UP POWER SUPP...

Page 93: ...trol System AYC IGNITION SWITCH IG1 BATTERY SUNROOF SEAT BELT WARNING LAMP METER AND GAUGE FOOT LAMP RADIO COMBINATION METER DEDICATED FUSE STOP LAMP SWITCH STOP LAMP ENGINE ECU ENGINE CONTROL SYSTEM...

Page 94: ...CIRCUIT DIAGRAM Active Yaw Control System AYC VEHICLESWITH ABS MOTOR RELAY ABS FRONT SPEED SENSOR REARSPEEDSENSOR ANTI LOCK BRAKE SYSTEM FRONT VIEW B 90 ACTIVE YAW CONTROL SYSTEM AYC CONTINUED...

Page 95: ...CIRCUIT DIAGRAM Active Yaw Control System AYC VEHICLES WITHOUT ABS FRONT SPEED SENSOR REAR SPEED SENSOR STEERING ANGLE SENSOR MULTI PURPOSE FUSE B 91...

Page 96: ...CIRCUIT DIAGRAM Active Yaw Control System AYC FUSIBLE LINK AYC RELAY PROPOR TIONING VALVE DIRECTION VALVE AYC MOTOR FRONT VIEW B 92 ACTIVE YAW CONTROL SYSTEM AYC CONTINUED...

Page 97: ...CIRCUIT DIAGRAM Active Yaw Control System AYC CENTRAL DOOR LOCKING SYSTEM VEHICLES WITH KEYLESS ENTRY SYSTEM FULLY AUTOMATIC AIR CONDITIONER ACCUMULATOR PRESSURE SWITCH DIAGNOSIS CONNECTOR B 93...

Page 98: ...rcooler Water Spray System IGNITION SWITCH IG2 VEHICLES WITHOUT ABS AND AYC VEHICLESWITH ABS OR AYC ACTIVE YAWCONTROL SYSTEM ANTI LOCK BRAKE SYSTEM WATER SPRAY SWITCH WATER SPRAY MOTOR B 94 INTERCOOLE...

Page 99: ...COOLING SYSTEM 34 ROOM LAMP AND LUGGAGE COMPARTMENT LAMP 36 TURN SIGNAL LAMP AND HAZARD LAMP 38 STOP LAMP 41 BACK UP LAMP 42 OIL PRESSURE WARNING LAMP 43 CENTRAL DOOR LOCKING SYSTEM VEHICLES WITH KEY...

Page 100: ...nator A 09 1 B Starter A 10 1 Starter A 12 2 B Fuel pressure solenoid valve A 16 4 B Throttle position sensor A 18 6 B Idle speed control servo A 19 3 B Vehicle speed sensor A 20 4 B Windshield wiper...

Page 101: ...A 35 2 BR Outside air temperature sensor vehicles with fully automatic air conditioner A 38 2 B Engine coolant temperature sensor A 39 1 B Engine coolant temperature gauge unit A 45 1 Horn RH A 46 1...

Page 102: ...ck up lamp switch A 73 1 L Engine speed detection connector A 74 1 B Fuel pump check connector A 76 6 Valve relay vehicles with ABS A 77 5 Motor relay vehicles with ABS A 78 2 GR Side turn signal lamp...

Page 103: ...106 1 B A C compressor assembly A 107 2 BR Front turn signal lamp RH A 110 3 GR Ignition coil 1 A 111 3 GR Ignition coil 2 A 112X 4 Radiator fan relay HI A 113X 4 Condenser fan relay LO A 114X 4 Conde...

Page 104: ...matic air conditioner B 06 6 Air outlet change over damper motor and potentiometer vehicles with fully auto matic air conditioner B 07 8 Blower switch vehicles with manual air conditioner B 08 25 Mete...

Page 105: ...31 1 Glass antenna amplifier B 32 19 B Jumper connector 5 B 33 2 Blower motor vehicles with fully auto matic air conditioner B 34 4 Blower high speed relay vehicles with fully automatic air conditione...

Page 106: ...les with manual air conditioner B 42 2 Blower switch illumination lamp vehicles with heater or manual air conditioner B 43 6 B Defogger switch vehicles with heater or manual air conditioner B 44 6 Bod...

Page 107: ...U B 61 12 Y Engine ECU B 62 22 Y Engine ECU B 63 2 Blower motor vehicles with heater or manual air conditioner B 64 13 Control harness and body harness combination B 65 16 B Control harness and body h...

Page 108: ...05 6 Body harness and rear door harness RH combination D 06 22 Body harness and rear harness combina tion D 07 6 Sunroof switch D 08 8 Room lamp vehicles with sunroof D 09 1 Map lamp D 10 18 Sunroof...

Page 109: ...2 B Rear speed sensor RH vehicles with ABS D 20 3 B Acceleration sensor vehicles with ABS D 21 1 B Parking brake switch D 27 2 Body harness and rear harness combina tion vehicles with AYC D 31 2 Water...

Page 110: ...ar wiper motor F 12 1 B Rear door switch RH F 13 2 Highmounted stop lamp installed onrear spoiler F 15 6 Rear combination lamp RH F 16 2 GR Licence plate lamp RH F 17 1 B Luggage compartment lamp swit...

Page 111: ...SINGLE PART INSTALLATION POSITION RELAY Name Symbol Name Symbol AYC relay B Fuel pump relay No 2 B Condenser fan motor relay HI A Radiator fan motor relay HI A Condenser fan motor relay LO A Radiator...

Page 112: ...sensor B Acceleration sensor longitudinal vehicles with ABS and AYC I Outside air temperature sensor vehicles with fully automatic air conditioner F Air flow sensor D O2 sensor E Camshaft position sen...

Page 113: ...or B Knock sensor C Throttle position sensor D Airflow sensor E O2 sensor F Outside air temperature sensor G Engine coolant temperature sensor Camshaft position sensor H Steering angle sensor I Accele...

Page 114: ...solenoid valve C Waste gate solenoid valve D Rear combination lamp RH Direction valve Proportioning valve C 16 SOLENOID VALVE Name Symbol Name Symbol Direction valve vehicles with AYC D Secondary air...

Page 115: ...se SINGLE PART INSTALLATION POSITION C 17 CHECK CONNECTOR AND SPARE CONNECTOR Engine speed check connector Fuel pump check connector FUSIBLE LINK AND FUSE Vehicles with AYC vehicles without ABS Fusibl...

Page 116: ...SINGLE PART INSTALLATION POSITION Ground Cable Ground C 18 GROUND CABLE GROUND...

Page 117: ...NTRALIZED JUNCTION CENTRALIZED RELAY Connector No Name Connector No Name A 82X Radiator fan motor relay LO A 113X Condenser fan motor relay LO A 112X Radiator fan motor relay HI A 114X Condenser fan m...

Page 118: ...YSTEM ACTIVE YAW CONTROL SYSTEM DEDICATED FUSE RELAY BOX IN ENGINE COMPARTMENT HEATER AND MANUAL AIR CONDITIONER FULLY AUTOMATICAIR CONDITIONER COOLING SYSTEM DEDICATED FUSE A C RELAY BOX IN ENGINE CO...

Page 119: ...D HAZARD LAMP ACTIVE YAW CONTROL SYSTEM ANTILOCK BRAKE SYSTEM STOP LAMP CLOCK AND MULTI DISPLAY SUNROOF CIGARETTE LIGHTER AND ASHTRAY ILLUMINATION LAMP METER AND GAUGE TURN SIGNAL LAMP AND HAZARD LAMP...

Page 120: ...RNING LAMP SUNROOF METER AND GAUGE CHARGING SYSTEM CENTRAL DOOR LOCKING SYSTEM TAIL LAMP POSITION LAMP LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER FUEL WARNING LAMP BRAKE WARNING LAMP RADIO SPARE C...

Page 121: ...Y ILLUMINATION LAMP ELECTRIC RETRACT ABLE REMOTE CONTROLLED DOOR MIRROR ELECTRICALLY REMOTE CON TROLLED DOOR MIRROR CLOCK AND MULTI DISPLAY CENTRAL DOOR LOCKING SYS TEM VEHICLES WITH KEYLESS ENTRY SYS...

Page 122: ...DER ILLUMINATIONLAMP IGNITION KEY REMINDER BUZZER ENGINE CONTROL SYSTEM CLOCK AND MULTI DISPLAY METER AND GAUGE CENTRAL DOOR LOCKING SYSTEM TAIL LAMP POSITION LAMP LICENCE PLATE LAMP AND LIGHTING MONI...

Page 123: ...CIRCUIT DIAGRAM Starting System BATTERY IGNITION SWITCH ST ENGINE CONTROL SYSTEM STARTER C 25 STARTING SYSTEM...

Page 124: ...2 NOISE CON DENSER INPUT SIGNAL IDLE SWITCH IGNITION SWITCH ST CAM POSITION SENSOR INTAKE AIR TEMPERATURE SENSOR CRANK ANGLE SENSOR VEHICLE SPEED SENSOR ENGINE COOLANT TEMPERATURE SENSOR BAROMETRIC P...

Page 125: ...NK IGNITION SWITCH IG1 TAIL LAMP POSITION LAMP LICENCE PLATE LAMP AND LIGHTING MONITOR BUZZER POWER SUPPLY FOG LAMP HEADLAMP ENGINE CONTROL UNIT ALTERNATOR RELAY COMBINATION METER STATOR COIL FIELD CO...

Page 126: ...l System FUSIBLE LINK FUSIBLE LINK IGNITION SWITCH IG1 VACANT TERMINAL COMBINATION METER ENGINE CONTROL RELAY ACTIVE YAW CONTROLSYSTEM ANTI LOCK BRAKE SYSTEM ENGINE ECU POWER SUPPLY BACK UP POWER SUPP...

Page 127: ...CIRCUIT DIAGRAM Engine Control System FUEL PUMP RELAY FUEL PUMP RESISTOR FUEL PUMP RELAY NO 2 FUEL PUMP IGNITION SYSTEM C 29...

Page 128: ...Control System ENGINE CONTROL RELAY CAMSHAFT POSITION SENSOR CRANK ANGLE SENSOR IDLESPEED CONTROL SERVO ENGINE ECU O2 SENSOR IDLE SWITCH THROTTLE POSITION SENSOR FRONT VIEW FRONT VIEW C 30 ENGINE CON...

Page 129: ...rol System RESISTOR FOR INJECTOR INJECTOR MULTI PURPOSE FUSE CENTRAL DOOR LOCKING SYSTEM VEHICLES WITH KEYLESS ENTRY SYSTEM FULLY AUTOMATIC AIR CONDITIONER DIAGNOSIS CONNECTOR DIAGNOSIS CONNECTOR INJE...

Page 130: ...OL SERVO ENGINE ECU ENGINE COOLANT TEMPERATURE SENSOR AIR FLOW SENSOR INTAKE AIR TEMPERATURE SENSOR BAROMETRIC PRES SURE SENSOR ENGINE ECU METER AND GAUGE RADIO KNOCK SENSOR VEHICLE SPEED SENSOR POWER...

Page 131: ...ROL SERVO IGNITION SWITCH ST FUEL PRESSURE SOLENOID VALVE WASTE GATE SOLENOID VALVE SECONDARY AIR CONTROL SOLENOID VALVE STARTING SYSTEM AIR CONDITIONER COOLING SYSTEM IGNITION SYSTEM METER AND GAUGE...

Page 132: ...SWITCH IG2 RADIATOR FAN MOTOR RELAY HI RADIATOR FAN MOTOR RELAY LO RADIATOR FAN MOTOR INPUT SIGNAL A C SWITCH IDLE SWITCH CRANK ANGLE SENSOR VEHICLE SPEED SENSOR ENGINE COOLANT TEMPERATURE SENSOR THR...

Page 133: ...GRAM Cooling System FUSIBLE LINK DEDICATED FUSE HEATER AND MANUAL AIR CONDITIONER FULLY AUTOMATIC AIR CONDITIONER CONDENSER FAN MOTOR RELAY HI DEDICATED FUSE CONDENSER FAN MOTOR RELAY LO CONDENSER FAN...

Page 134: ...MP ROOM LAMP ROOM LAMP COMBINATION METER MAP LAMP DEFOGGER VEHICLES WITHOUT KEYLESS ENTRY SYSTEM VEHICLESWITH KEYLESS ENTRY SYSTEM DIODE LUGGAGE COMPARTMENT LAMP CENTRAL DOOR LOCKING SYSTEM VEHICLES W...

Page 135: ...C 37 NOTES...

Page 136: ...M HEADLAMP DEDICATED FUSE FOG LAMP COLUMN SWITCH LIGHTING SWITCH HAZARD SWITCH DEDICATED FUSE NOTE CLOCK AND MULTI DISPLAY CIGARETTE LIGHTER AND ASHTRAY ILLUMINATION LAMP ELECTRIC RETRACTABLE REMOTE C...

Page 137: ...CIRCUIT DIAGRAM Turn signal Lamp and Hazard Lamp TURN SIGNAL AND HAZARD FLASHER UNIT HAZARD SWITCH SIDE TURN SIGNAL LAMP FRONT TURN SIGNALLAMP SIDE TURN SIGNAL LAMP C 39...

Page 138: ...p and Hazard Lamp HAZARDSWITCH TURN SIGNAL AND HAZARD FLASHER UNIT REAR COMBINATION LAMP TURN RH REAR COMBINATION LAMP TURN LH COLUMN SWITCH TURN SIGNAL LAMP SWITCH COMBINATION METER C 40 TURN SIGNAL...

Page 139: ...DEDICATED FUSE STOP LAMP SWITCH ANTI LOCK BRAKE SYSTEM INSTALLED ON REAR SPOILER INSTALLED ON REAR SHELF REAR COMBINATION LAMP STOP RH STOP LH HIGH MOUNTED STOP LAMP VACANT CONNECTOR SOME MODELS HIGH...

Page 140: ...CIRCUIT DIAGRAM Back up Lamp IGNITION SWITCH IG1 BACK UP LAMP SWITCH REARCOMBINATION LAMP BACK UP LH REARCOMBINATION LAMP BACK UP RH C 42 BACK UP LAMP...

Page 141: ...CIRCUIT DIAGRAM Oil Pressure Warning Lamp IGNITION SWITCH IG1 COMBINATION METER CHARGING SYSTEM C 43 OIL PRESSURE WARNING LAMP...

Page 142: ...ntral Door Locking System Vehicles with Keyless Entry System FUSIBLE LINK IGNITION SWITCH IG1 RECEIVER KEY REMINDER SWITCH DOOR LOCK ACTUATOR FRONT RH C 44 CENTRAL DOOR LOCKING SYSTEM VEHICLES WITH KE...

Page 143: ...CIRCUIT DIAGRAM Central Door Locking System Vehicles with Keyless Entry System DOOR LOCK ACTUATOR FRONT LH DOOR LOCK ACTUATOR REAR RH DOOR LOCK ACTUATOR REAR LH C 45...

Page 144: ...tem MULTI PURPOSE FUSE VEHICLES WITHOUT SUNROOF VEHICLES WITH SUNROOF ROOM LAMP VEHICLESWITH MAP LAMP ROOM LAMP MAPLAMP COMBINATION METER DIODE FRONT DOOR SWITCH REAR DOOR SWITCH FRONT VIEW SUNROOF C...

Page 145: ...tem Vehicles with Keyless Entry System IGNITION SWITCH ACC MULTI PURPOSE FUSE RECEIVER RADIO RECEIVING ANTENNA ANTI LOCK BRAKE SYSTEM ENGINE CONTROL SYSTEM FULLY AUTOMATIC AIR CONDITIONER CONTROL CIRC...

Page 146: ...ditioner FUSIBLE LINK CHARGING SYSTEM POWER SUPPLY HEADLAMP DEDICATED FUSE FOG LAMP COLUMN SWITCH LIGHTING SWITCH FUSIBLE LINK IGNITION SWITCH IG2 BLOWER MOTOR RELAY BLOWER MOTOR RESISTOR BLOWER SWITC...

Page 147: ...CIRCUIT DIAGRAM Heater and Manual Air Conditioner COLUMN SWITCH BLOWER SWITCH HEATER CONTROL PANEL ILLUMINATION LAMP A C SWITCH BLOWER SWITCH AUTOMATIC COMPRESSOR ECU C 49...

Page 148: ...CH IG2 RADIATOR FAN MOTOR RELAY HI RADIATOR FAN MOTOR RELAY LO RADIATOR FAN MOTOR INPUT SIGNAL A C SWITCH IDLE SWITCH CRANK ANGLE SENSOR VEHICLE SPEED SENSOR ENGINE COOLANT TEMPERATURE SENSOR THROTTLE...

Page 149: ...CIRCUIT DIAGRAM Heater and Manual Air Conditioner FUSIBLE LINK DEDICATED FUSE CONDENSER FAN MOTOR RELAY HI DEDICATED FUSE CONDENSER FAN MOTOR RELAY LO CONDENSER FAN MOTOR C 51...

Page 150: ...ir Conditioner AUTOMATIC COMPRESSOR ECU FUSIBLE LINK DUAL PRESSURE SWITCH DEDICATED FUSE A C COMPRESSOR RELAY ENGINE ECU REFRIGERANT TEMPERATURE SWITCH A C COMPRESSOR AND MAGNETIC CLUTCH C 52 HEATER A...

Page 151: ...C 53 NOTES...

Page 152: ...y Automatic Air Conditioner FUSIBLE LINK IGNITION SWITCH IG2 BLOWER MOTOR RELAY BLOWER MOTOR BLOWER HIGH SPEED RELAY BACK UP POWER SUPPLY POWER TRAN SISTOR DRIVE CIRCUIT POWER SUPPLY C 54 FULLY AUTOMA...

Page 153: ...Conditioner FUSIBLE LINK CHARGING SYSTEM POWER SUPPLY HEADLAMP DEDICATED FUSE POWER TRANSISTOR BLOWER MOTOR BLOWERHIGH SPEED RELAY FOG LAMP COLUMN SWITCH LIGHTING SWITCH POWER TRAN SISTOR DRIVE CIRCUI...

Page 154: ...ER POTENTIOMETER AIR THERMO SENSOR HEATER WATER TEMPERATURE SENSOR DEDICATED IC AIR OUTLET CHANGEOVER DAMPER MOTOR AIR MIX DAMPER MOTOR INSIDE AND OUTSIDE AIR CHANGEOVER DAMPER MOTOR DEDICATED IC DEDI...

Page 155: ...omatic Air Conditioner OUTSIDEAIR TEMPERATURE SENSOR SUNLIGHT SENSOR DEFOGGER FUSIBLE LINK ANTI LOCK BRAKE SYSTEM ENGINE CONTROL SYSTEM CENTRAL DOOR LOCK ING SYSTEM VEHICLES WITH KEY LESS ENTRY SYSTEM...

Page 156: ...CH IG2 RADIATOR FAN MOTOR RELAY HI RADIATOR FAN MOTOR RELAY LO RADIATOR FAN MOTOR INPUT SIGNAL A C SWITCH IDLE SWITCH CRANK ANGLE SENSOR VEHICLE SPEED SENSOR ENGINE COOLANT TEMPERATURE SENSOR THROTTLE...

Page 157: ...CIRCUIT DIAGRAM Fully Automatic Air Conditioner FUSIBLE LINK DEDICATED FUSE CONDENSER FAN MOTOR RELAY HI DEDICATED FUSE CONDENSER FAN MOTOR RELAY LO CONDENSER FAN MOTOR C 59...

Page 158: ...Automatic Air Conditioner DUAL PRESSURE SWITCH DEDICATED FUSE DEDICATED FUSE A C COMPRESSOR RELAY REFRIGERANT TEMPERATURESWITCH A C COMPRESSOR AND MAGNETIC CLUTCH ENGINE ECU C 60 FULLY AUTOMATIC AIR...

Page 159: ...RELAY IGNITION SWITCH ACC IN CASE OF OPERATION INTERVAL FIXED TYPE INTERMITTENT WIPER VARIABLE INTER MITTENT WIPER CONTROL SWITCH WINDSHIELD WASHER SWITCH WINDSHIELD WIPER SWITCH WINDSHIELD WASHER MO...

Page 160: ...CIRCUIT DIAGRAM Rear Wiper and Washer IGNITIONSWITCH ACC WINDSHIELDWIPER AND WASHER COLUMN SWITCH REAR INTERMITTENT WIPER RELAY REAR WASHER MOTOR REAR WIPER MOTOR C 62 REAR WIPER AND WASHER...

Page 161: ...C 63 NOTES...

Page 162: ...CHARGING SYSTEM POWERSUPPLY HEADLAMP DEDI CATED FUSE FOG LAMP COLUMN SWITCH LIGHTING SWITCH DEFOGGER SWITCH IGNITIONSWITCH IG2 FUSIBLE LINK DEFOGGER RELAY VEHICLES WITHOUT GLASS ANTENNA VEHICLES WITH...

Page 163: ...ter Vehicles without Fully Automatic Air Conditioner PRINTED HEATER WIRE DOOR MIRROR PRINTED HEATER WIRE DEFOGGER RELAY ROOM LAMP AND LUGGAGE COMPARTMENT LAMP VEHICLES WITH GLASS ANTENNA VEHICLES WITH...

Page 164: ...er Vehicles with Fully Automatic Air Conditioner IGNITIONSWITCH IG2 FUSIBLE LINK DEFOGGER RELAY VEHICLESWITHOUT GLASS ANTENNA VEHICLES WITH GLASS ANTENNA DEFOGGER C 66 DEFOGGER AND DOOR MIRROR HEATER...

Page 165: ...eater Vehicles with Fully Automatic Air Conditioner PRINTED HEATER WIRE DOOR MIRROR PRINTED HEATER WIRE DEFOGGER RELAY ROOM LAMP AND LUGGAGE COMPARTMENT LAMP VEHICLES WITH GLASS ANTENNA CHOKE COIL VEH...

Page 166: ...STEM POWER SUPPLY HEADLAMP DEDICATED FUSE FOG LAMP COLUMN SWITCH LIGHTING SWITCH SPARE CONNECTOR FOR RADIO IGNITION SWITCH ACC CENTRAL DOOR LOCKING SYS TEM VEHICLES WITH KEYLESS ENTRY SYSTEM FUSIBLELI...

Page 167: ...ANTENNA ANTENNA FEEDER LINE VEHICLES WITH GLASS ANTENNA REAR WINDOW GLASS ANTENNA GLASS ANTENNA AMPLIFIER ANTENNA FEEDER LINE METER AND GAUGE SPARECONNECTORFOR DOOR SPEAKER IGNITIONSWITCH IG1 SUNROOF...

Page 168: ...INK CHARGING SYSTEM POWER SUPPLY HEADLAMP DEDICATED FUSE FOG LAMP COLUMN SWITCH LIGHTING SWITCH CENTRAL DOOR LOCKING SYS TEM VEHICLES WITH KEYLESS ENTRY SYSTEM VEHICLESWITH POLE ANTENNA POLEANTENNA AN...

Page 169: ...GLASSANTENNA REAR WINDOW GLASS ANTENNA VEHICLES WITH GLASS DIVERSITY ANTENNA REAR WINDOW GLASS ANTENNA GLASS ANTENNA AMPLIFIER ANTENNA FEEDER LINE TWEETER LH VEHICLES WITH 6 SPEAKERS DOOR SPEAKER LH D...

Page 170: ...aker MULTI PURPOSE FUSE MULTI PURPOSE FUSE CD CHANGER DIN CABLE RADIO AND TAPE PLAYER IGNITION SWITCH IG1 SUNROOF SEAT BELT WARNING LAMP METER AND GAUGE ENGINE CONTROL SYSTEM VEHICLE SPEED SENSOR C 72...

Page 171: ...C 73 NOTES...

Page 172: ...CIRCUIT DIAGRAM Anti lock Brake System ABS BATTERY FUSIBLE LINK DEDICATED FUSE STOP LAMP SWITCH STOP LAMP ENGINE CONTROL SYSTEM BACK UP POWER SUPPLY C 74 ANTI LOCK BRAKE SYSTEM ABS...

Page 173: ...CIRCUIT DIAGRAM Anti lock Brake System ABS IGNITION SWITCH IG2 ACCELERATION SENSOR LATERAL ACTIVE YAW CONTROL SYSTEM INTERCOOLER WATER SPRAY SYSTEM C 75...

Page 174: ...IT DIAGRAM Anti lock Brake System ABS IGNITION SWITCH IG1 FUSIBLE LINK MULTI PURPOSE FUSE COMBINATION METER VALVE RELAY MOTOR RELAY DIODE ACTIVE YAW CONTROL SYSTEM C 76 ANTI LOCK BRAKE SYSTEM ABS CONT...

Page 175: ...CIRCUIT DIAGRAM Anti lock Brake System ABS ACCELERATION SENSOR LONGITUDINAL ACCELERATION SENSOR LATERAL ACTIVE YAW CONTROL SYSTEM FRONT SPEED SENSOR REAR SPEED SENSOR C 77...

Page 176: ...INLET VALVE FRONT LH FRONT RH REAR LH REAR RH OUTLET VALVE FRONT LH FRONT RH REAR LH REAR RH CENTRAL DOOR LOCKING SYSTEM VEHICLES WITH KEYLESS ENTRY SYSTEM FULLY AUTOMATIC AIR CONDITIONER MULTI PURPO...

Page 177: ...C 79 NOTES...

Page 178: ...stem AYC FUSIBLE LINK IGNITION SWITCH IG2 INTERCOOLER WATER SPRAY SYSTEM ACCELERA TION SENSOR LATERAL ACCEL ERATION SENSOR LONGITU DINAL ENGINE CONTROL SYSTEM ANTI LOCK BRAKE SYSTEM BACK UP POWER SUPP...

Page 179: ...w Control System AYC IGNITION SWITCH IG1 BATTERY SUNROOF SEAT BELT WARNING LAMP METER AND GAUGE RADIO COMBINATION METER DEDICATED FUSE STOP LAMP SWITCH STOP LAMP ENGINE ECU ENGINE CONTROL SYSTEM THROT...

Page 180: ...CIRCUIT DIAGRAM Active Yaw Control System AYC VEHICLESWITH ABS MOTOR RELAY ABS FRONT SPEED SENSOR REARSPEEDSENSOR ANTI LOCK BRAKE SYSTEM FRONT VIEW C 82 ACTIVE YAW CONTROL SYSTEM AYC CONTINUED...

Page 181: ...CIRCUIT DIAGRAM Active Yaw Control System AYC VEHICLESWITHOUT ABS FRONT SPEED SENSOR REAR SPEED SENSOR STEERING ANGLE SENSOR MULTI PURPOSE FUSE C 83...

Page 182: ...CIRCUIT DIAGRAM Active Yaw Control System AYC FUSIBLE LINK AYC RELAY PROPORTIONING VALVE DIRECTION VALVE AYC MOTOR FRONT VIEW C 84 ACTIVE YAW CONTROL SYSTEM AYC CONTINUED...

Page 183: ...T DIAGRAM Active Yaw Control System AYC MULTI PURPOSE FUSE CENTRAL DOOR LOCKING SYSTEM VEHICLES WITH KEYLESS ENTRY SYSTEM FULLY AUTOMATIC AIR CONDITIONER ACCUMULATOR PRESSURE SWITCH DIAGNOSIS CONNECTO...

Page 184: ...Water Spray System IGNITION SWITCH IG2 VEHICLES WITHOUT ABS AND AYC VEHICLESWITH ABS OR AYC ACTIVE YAWCONTROL SYSTEM ANTI LOCK BRAKE SYSTEM WATER SPRAY SWITCH WATER SPRAY MOTOR HY807002 538 C 86 INTE...

Page 185: ...MODELS 2 00 1 GENERAL CONTENTS...

Page 186: ...controlled fuel SRGF 97 GSR 16 valves intercooler turbo 4WD 5M T controlled fuel injection MPI LANCER EVOLUTION V Model code Class code Model year Grade Engine model Transmission model Fuel supply sys...

Page 187: ...er Check 5 3 Lash Adjuster Check 5 4 Lash Adjuster Replacement 7 5 Ignition Timing Check 7 6 Idle Speed Check and Idle Mixture Check 7 7 Compression Pressure Check 7 8 Manifold Vacuum Check 8 CRANKSHA...

Page 188: ...ference of all cylinders kg cm2 Max 1 0 Intake manifold vacuum kPa mmHg Min 55 410 Cylinder head bolt shank length mm 99 4 SEALANTS Items Specified sealants Rocker cover Semi drying sealant THREEBOND...

Page 189: ...oil seal installer Pressfitting the camshaft oil seal MD998727 Oil pan remover Removing the oil pan MD998781 Flywheel stopper Securing the flywheel or drive plate MD998776 Crankshaft rear oil seal in...

Page 190: ...pporting the engine assembly during removal and installation of the transmission MD991453 Engine hanger assembly ENGINE ADJUSTMENTS 1 DRIVE BELT TENSION CHECK NOTE Use of the auto tensioner eliminates...

Page 191: ...ed in oil for these reasons gets into the high pressure chamber of the lash adjuster the air in the high pressure chamber is compressed to shrink the lash adjuster excessively while the valve is openi...

Page 192: ...eak down test and bleeding procedures refer to ENGINE WORKSHOP MANUAL If the rocker arm is felt binding and cannot be pushed downward as you push it the lash adjuster is operational Check for other po...

Page 193: ...ection check that the engine oil starter and battery are normal In addition set the vehicle to the pre inspection condition 2 Remove all of the spark plugs 3 Disconnect the crank angle sensor connecto...

Page 194: ...ace b If the compression does not rise after oil is added the cause is a burnt or defective valve seat or pressure is leaking from the gasket 9 Connect the crank angle sensor connector 10 Install the...

Page 195: ...djustment Refer to P 11 4 D Under Cover Installation 1 2 25 2 5 Unit Nm kgf m Removal steps AA 1 Drive belt 2 Crankshaft pulley REMOVAL SERVICE POINT AA DRIVE BELT REMOVAL 1 Align the hole in the auto...

Page 196: ...ng Belt Removal and Installation Refer to P 11 21 22 2 2 Unit Nm kgf m 10 1 0 9 0 9 3 4 0 35 20 2 0 88 9 0 12 15 1 2 1 5 1 5 3 4 6 2 14 15 17 16 13 12 11 10 9 8 7 Removal steps 1 Breather hose connect...

Page 197: ...side 26 3 mm REMOVAL SERVICE POINT AA CAMSHAFT SPROCKET REMOVAL INSTALLATION SERVICE POINTS AA CAMSHAFT INSTALLATION 1 Apply engine oil to the cams and journals of the camshaft 2 Mount the camshaft o...

Page 198: ...entire periphery of the oil seal lip 2 Pressfit the oil seal as shown DA CAMSHAFT SPROCKET INSTALLATION As you did during removal secure the camshaft sprocket with the special tool and tighten bolt t...

Page 199: ...ne Oil Draining and Supplying A 6 8 mm B 6 10 mm Identification of bolt location Semi drying sealant THREEBOND 1207D 4 mm Bolt hole Groove 8 A B B 8 B B B 3 7 8 6 4 5 1 2 39 4 0 39 44 4 0 4 5 7 0 7 26...

Page 200: ...AIN PLUG GASKET INSTALLATION Install the drain plug gasket in the direction so that it faces as shown in the illustration BA OIL RETURN PIPE GASKET INSTALLATION Install the gasket with the printed por...

Page 201: ...oil 5 Crankshaft front oil seal removal steps D Timing belt and timing belt B Refer to P 11 21 D Crank angle sensor Refer to GROUP 16 1 Crankshaft sprocket B 2 Key CA 3 Crankshaft front oil seal Crank...

Page 202: ...seal case as shown in the illustration BA FLYWHEEL ASSEMBLY INSTALLATION Use the special tool to hold the flywheel in the same manner as removal and install the bolt Tighten the bolts to the specific...

Page 203: ...ation 6 Accelerator Cable Adjustment O ring Delivery pipe Engine oil 12 15 1 2 1 5 5 9 0 9 5 0 5 3 0 3 10 1 0 19 14 15 3 16 18 10 17 8 9 8 11 8 7 20 1 2 Unit Nm kgf m 18 6 3 13 12 4 Removal steps 1 Ce...

Page 204: ...8 0 0 2 0 90_ 90_ 22 22 23 10 mm 10 mm Removal steps 21 PCV hose connection 22 Rocker cover 23 Semi circular packing 24 Starter 25 Oil return pipe CA 26 Oil return pipe gasket 27 Vacuum tank solenoid...

Page 205: ...face 2 Install so that the shapes of the cylinder head holes match the shapes of the respective cylinder head gasket holes BA CYLINDER HEAD BOLT INSTALLATION 1 When installing the cylinder head bolts...

Page 206: ...head bolt will be loosened 2 If it is more than 90_ remove the head bolt and repeat the procedure from step 1 CA OIL RETURN PIPE GASKET INSTALLATION Install the gasket with the printed portion toward...

Page 207: ...ng belt KA 6 Tensioner pulley 7 Tensioner arm JA 8 Auto tensioner 9 Idle pulley 10 Crankshaft position sensor AB IA 11 Oil pump sprocket AC HA 12 Crankshaft bolt AD 13 Crankshaft sprocket 14 Sensing b...

Page 208: ...aution The camshaft sprocket on the exhaust side can turn very easily because of the valve spring tension Use care not to allow your fingers to get caught by the sprocket 3 Loosen the lock nut of the...

Page 209: ...AL AG CRANKSHAFT SPROCKET B REMOVAL If it is difficult to remove the sprocket use the special tool AH CAMSHAFT SPROCKET BOLT LOOSENING Use a wrench to hold the hexagonal part of the camshaft and then...

Page 210: ...worn down and rubber exposed tooth width reduced 8 Missing tooth AUTO TENSIONER 1 Check the auto tensioner for possible leaks and replace as necessary 2 Check the rod end for wear or damage and replac...

Page 211: ...et with a tool damages the sprocket BA ENGINE SUPPORT BRACKET LEFT INSTALLATION Coat the bolts illustrated with sealant before tightening Specified sealant THREEBOND 1207F or equivalent CA SEALANT APP...

Page 212: ...ontacting surface 2 Install the spacer with the chamfered end toward the oil seal Mounting in the reverse direction can damage the oil seal lip FA COUNTERBALANCE SHAFT SPROCKET INSTALLATION GATIMING B...

Page 213: ...IA OIL PUMP SPROCKET INSTALLATION 1 Block the counterbalance shaft in the same way as at the disassembly to prevent it from turning 2 Install the oil pump sprocket 3 Apply a proper amount of engine oi...

Page 214: ...TE Even if the timing marks on the sprocket and the rocker cover are brought into alignment the exhaust camshaft is forced back by the valve spring tension It is stabilized at a position one tooth bef...

Page 215: ...ection 7 Fit the timing belt over the exhaust side camshaft sprocket and secure it at the illustrated position using a paper clip 8 Turn the intake side camshaft sprocket as shown to a position where...

Page 216: ...p sprocket and exhaust camshaft sprocket are all offset one tooth from the corresponding timing marks in the counterclockwise direction 14 Using the special tool turn the tensioner pulley in the illus...

Page 217: ...becomes 3 5 Nm 0 36 kgf m then secure it by tightening the retaining bolt 20 Remove the special tool attached in step 16 21 Rotate the crankshaft clockwise 2 turns Then leave it intact 15 minutes 22...

Page 218: ...15 Intercooler 6 Strut Tower Bar Installation 7 Hood Installation O ring Delivery pipe 1 2 3 4 5 6 7 8 9 10 11 18 12 Engine oil 5 0 5 Unit Nm kgf m 10 12 1 0 1 2 17 16 14 13 10 12 1 0 1 2 15 3 0 3 17...

Page 219: ...sion inspection Refer to P 11 4 AA 23 Drive belt AB 24 A C compressor AC 25 Power steering oil pump D Transmission assembly 26 A C relay box 27 A C receiver bracket mounting bolt 28 Oil pressure hose...

Page 220: ...e compressor from the compressor bracket with the hose still attached NOTE Place the removed A C compressor where it will not be a hindrance when removing and installing the engine assembly and tie it...

Page 221: ...ne mount bracket while adjusting the position of the engine 2 Support the engine with the garage jack 3 Remove the chain block and support the engine assembly with the special tools CA HIGH PRESSURE F...

Page 222: ...LUBRICANTS 2 ENGINE OIL COOLER 2 12 1 ENGINE LUBRICATION CONTENTS...

Page 223: ...EMOVAL AND INSTALLATION Pre removal and Post installation Operation 1 Engine Oil Removal and Refilling 2 Front Bumper Removal and Installation Refer to GROUP 51 3 Unit Nm kgf m 12 1 2 39 44 4 0 4 5 29...

Page 224: ...tion Sensor TPS Adjustment 30 2 Fixed SAS Adjustment 30 3 Basic Idle Speed Adjustment 30 4 Fuel Pressure Measurement 30 5 MPI System Components Layout 31 6 Intake Air Temperature Sensor Check 32 7 Eng...

Page 225: ...n switch ST D Vehicle speed sensor D A C switch D Power steering fluid pressure switch D Alternator FR signal Engine ECU L1 Oxygen sensor L2 Air flow sensor L3 Intake air tem peraturesensor L4 L5 L6 C...

Page 226: ...3 0 At 80_C 0 30 0 42 Coolant temperature sensor resistance k At 20_C 2 1 2 7 At 80_C 0 26 0 36 Fuel pressure kPa kgf cm2 When vacuum hose is connected 230 2 35 kPa kgf cm2 When vacuum hose is disconn...

Page 227: ...ustment of idle switch and throttle position sensor TPS MD998464 Test harness 4 pin square Inspection of oxygen sensor MD998463 Test harness 6 pin square D Inspection of idle speed control servo D Ins...

Page 228: ...ressure gauge set Red harness White harness MB991223 Inspection test herness set D Pin contact pressure inspection harness D Market tester contact probe for general connectors Measurement of terminal...

Page 229: ...ster Misfire Evolution V only 1 2 METHOD OF READING AND ERASING DIAGNOSIS CODES 1 Use the special tool to earth No 1 terminal diagnosis control terminal of the diagnosis connector 2 To check ABS syste...

Page 230: ...n sensor TPS No increase in fuel injection amount during acceleration due to the throttle position sensor signal Engine coolant temperature sensor Controls as if the engine coolant temperature is 80_C...

Page 231: ...k D Engine speed is 500 r min or more Set conditions D Sensor output frequency is 3 Hz or less for 4 seconds D Malfunction of the air flow sensor D Improper connector contact open circuit or short cir...

Page 232: ...G Check the harness wire between the engine ECUand the intake air temper ature sensor connector NG Repair OK Replace the engine ECU OK Check the following connector A 25 NG Repair NG Code No 14 Thrott...

Page 233: ...tch ON D Engine speed is approx 50 r min or more Set conditions D The sensor output voltage increases from 1 6 V or less corresponding to an engine coolant temperature of 40_C or more to 1 6 V or more...

Page 234: ...the harness wire between the crank angle sensor and the earth and repair if necessary Code No 23 Camshaft position sensor system Probable cause Range of Check D Ignition switch ON D Engine speed is a...

Page 235: ...en the engine ECU and the vehicle speed sensor connector NG Repair OK Check trouble symptom OK Check the following connectors A 19 B 62 NG Repair NG Check the harness wire between the engine ECU and t...

Page 236: ...switch ON OK 3 7 4 3V Altitude 0 m 3 2 3 8 V Altitude 1 200 m NG Measureattheairflowsensorcon nector A 25 D Disconnect the connector and measure at the harness side D Voltage between 1 and earth Igni...

Page 237: ...Check the harness wire between the detonationsensor and earth and repair if necessary Code No 41 Injector system Probable cause Range of Check D Engine speed is approx 50 1 000 r min D The throttle p...

Page 238: ...Check the spark plugs and spark plug cables D Check the compression pressure OK Check trouble symptom OK Check the following connectors A 110 A 111 NG Repair NG Check the harness wire between the eng...

Page 239: ...alternator connec tor D Connect the connector UsetestharnessMB991519 D Voltage between 4 blue clip and earth Engine Idling Radiator fan Stopped Headlamp OFF ON Brake lamp OFF ON Rear defogger switch...

Page 240: ...e engine stalls when the accelerator pedal is depressed or while it is being used Driving Hesitation Sag Hesitation is the delay in response of the vehicle speed engine speed that occurs when the acce...

Page 241: ...ensor 80 95_C D Lamps electric cooling fan and all accessories OFF 2 500 r min 46 86 Hz all accessories OFF D Transmission Neutral Engine is raced Frequency increases in response to racing 13 Intake a...

Page 242: ...rpm When engine coolant temper ature is 20_C 1 300 1 500 rpm When engine coolant temper ature is 40_C 1 150 1 350 rpm When engine coolant temper ature is 80_C 750 950 rpm 25 Barometric pressure Igniti...

Page 243: ...ion 4 D Lamps electric cooling fan and all accessories OFF D Transmission Neutral D Idle position switch ON D Engine Idling A C switch OFF ON Increases by 10 70 steps D Engine Idling When A C switch i...

Page 244: ...80_C 3 8 5 6 ms Injector drive time 3 D Engine coolant temperature 80 95_C Engine is idling 0 9 2 1 ms drive time 3 80 95_C D Lamps electric cooling fan and all accessories OFF 2 500 r min 0 7 1 9 ms...

Page 245: ...from battery voltage to 17 Stepper motor coil A2 for warming up from battery voltage to 0 6 V and from 0 6 V to battery voltage 5 Stepper motor coil B1 V to battery voltage 18 Stepper motor coil B2 6...

Page 246: ...ng after warming up When steering wheel is stationary Battery voltage When steering wheel is turned 0 3 V 38 Control relay Ignition switch OFF Battery voltage Ignition switch ON 0 3 V 39 Fuel pump rel...

Page 247: ...engine coolant temperature is 0_C 3 2 3 8 V When engine coolant temperature is 20_C 2 3 2 9 V When engine coolant temperature is 40_C 1 3 1 9 V When engine coolant temperature is 80_C 0 3 0 9 V 84 Thr...

Page 248: ...13 Body earth Engine ECU earth Continuity established 0 26 Body earth 60 12 Oxygen sensor heater EVOLUTION V only 11 18 at 20_C 72 92 Intake air temperature sensor 5 3 6 7 k When intake air temperatur...

Page 249: ...al 4G9 engine for the inspection 7 3 INJECTOR Observing waveforms displayed on the oscilloscope allows you to visually check the conditions of injector drive signals actually output from the engine EC...

Page 250: ...time invalid injection time Invalid injection time corrects operation time lag caused by a power supply voltage drop Solenoid coil counter emf When the signal from the engine ECU turns OFF counter emf...

Page 251: ...er and to terminal 6 yellow clip when the waveform is observed with no 4 cylinder 3 For the power supply voltage observe the waveform of the injector control signal at the same time Refer to P 13 26 f...

Page 252: ...all there should normally be a voltage drop of about 10 V Resistance of resistor is too small Resistance of injector is too large Point B Spike when plunger is fully open Refer to abnormal waveform ex...

Page 253: ...lever should be 0 45 mm 2 FIXED SAS ADJUSTMENT EVOLUTION IV Turn down one turn after the fixed SAS has touched the throttle lever EVOLUTION V Turn down 1 1 4 turns after the fixed SAS has touched the...

Page 254: ...il and power transistor unit L sensor and barometric pressure sensor Injector B Camshaft position sensor M ISC servo D Control relay and fuel pump relay P Oxygen sensor K Coolant temperature sensor E...

Page 255: ...hanged replace the air flow sensor assembly 7 ENGINE COOLANT TEMPERATURE SENSOR CHECK The engine coolant temperature sensor is located as shown on the left Standard value 2 1 2 7 k at 20_C 0 26 0 36 k...

Page 256: ...ctively Caution Make sure of the correct connections if a wrong connection is made a broken oxygen sensor results 6 Connect a digital voltmeter between terminal no 2 special tool black clip and termin...

Page 257: ...tor and Clip as illustrated below 4 From here on use the same procedure as with the conventional 4G9 engine for the check MD998741 MD998706 MB991607 Main hose Battery Injector Clip MD998746 Return hos...

Page 258: ...and terminal 5 and across terminal 4 and terminal 5 of fuel pump relay No 2 Jumper wire Continuity across terminals 2 and 5 Continuity across terminals 4 and 5 Connected No Yes Disconnected Yes No 4 I...

Page 259: ...o GROUP15 Intercooler 2 Fuel Leakage Check O ring 9 0 9 8 3 6 11 12 O ring 10 13 1 0 1 3 Engine oil 1 2 3 4 5 6 7 8 9 10 11 12 Unit Nm kgf m 4 Removal steps 1 Injector connector 2 PCV hose connection...

Page 260: ...Accelerator Cable Adjustment 3 4 2 6 1 7 19 1 9 5 Unit Nm kgf m 5 0 5 Removal steps 1 Accelerator cable connection 2 Throttle position sensor connector 3 Idle speed control servo connector 4 Vacuum h...

Page 261: ...14 1 ENGINE COOLING CONTENTS SERVICE SPECIFICATIONS 2 LUBRICANT 2 ON VEHICLE SERVICE 2 Coolant Replacement 2 THERMOSTAT 3 WATER PUMP 5 WATER HOSE AND WATER PIPE 6 RADIATOR 7...

Page 262: ...ICANT Items Brand Quantity dm3 Coolant capacity in condenser tank MITSUBISHI GENUINE DIA QUEEN SUPER LONG LIFE COOLANT 6 6 ON VEHICLE SERVICE COOLANT REPLACEMENT CYLINDER BLOCK DRAIN PLUG Unit Nm kgf...

Page 263: ...Hose Assembly Removal and Installation Refer to GROUP 15 Intercooler 4 3 5 1 Unit Nm kgf m 13 1 3 Removal steps AA BA 1 Radiator lower hose connection 2 Control wiring harness connection 3 Water inle...

Page 264: ...t fitting 2 Align the mating marks on the radiator hose and hose clamp and then connect the radiator hose INSPECTION THERMOSTAT CHECK 1 Immerse the thermostat in water and heat the water while stirrin...

Page 265: ...5 24 2 4 8 22 8 14 Bolt specifications 8 24 Screw diameter length mm 1 2 4 3 2 22 2 2 8 70 Unit Nm kgf m Removal steps 1 Alternator brace 2 Water pump 3 Water pump gasket AA 4 O ring INSTALLATION SER...

Page 266: ...15 AIR CONTROL VALVE 6 2 10 8 Semi drying sealant THREEBOND 1207F 5 7 f3mm 6 9 1 3 Unit Nm kgf m 24 2 4 48 4 9 10 1 0 14 11 12 13 1 3 41 4 2 13 1 3 10 1 0 24 2 4 41 4 2 13 4 Removal steps AA CA 1 Rad...

Page 267: ...adiator removal steps 1 Drain plug 2 Radiator cap 3 Overflow hose 4 Reserve tank 5 Reserve tank bracket AA AA 6 Radiator upper hose AA AA 7 Radiator lower hose 8 Radiator assembly 9 Lower insulator 10...

Page 268: ...of the water inlet or outlet fitting 2 Align the mating marks on the radiator hose and hose clamp and then connect the radiator hose Caution Fit the clamp on the hose at the same position as before I...

Page 269: ...ENGINE COOLING Radiator 14 9 Battery voltage Terminal number 1 2 3 4 When deenergized When energized Radiator fan motor relay HI...

Page 270: ...stem Check 3 3 Wastegate Actuator Check 4 4 Wastegate Solenoid Valve Check 4 5 Air Bypass Valve Check 4 6 Secondary Air Control System Check 5 7 Secondary Air Control Solenoid Valve Check 5 8 Secondar...

Page 271: ...oval and installation of oxygen sensor ON VEHICLE SERVICE 1 TURBOCHARGER BOOST PRESSURE CHECK Caution Carry out driving tests in a location where full throttle acceleration is possible with utmost saf...

Page 272: ...e way joint between the hose and solenoid valve 2 Connect a hand vacuum pump to the three way joint 3 Disconnect the hose black from the intake pipe nipple connected to the turbocharger compressor hou...

Page 273: ...1 OPERATION CHECK 1 Connect a hand vacuum pump to nipple A of the solenoid valve 2 Using jumper wires connect the solenoid valve terminal to battery terminals 3 Disconnecting and reconnecting the jump...

Page 274: ...se white stripe yellow stripe from the solenoid valve 2 Disconnect the harness connector 3 Connect a hand vacuum pump to nipple A of the solenoid valve 4 Using jumper wires connect the solenoid valve...

Page 275: ...ve to check for air passage Vacuum Air blowing direction Air passage 0 kPa vacuum notapplied A B No 40 kPa 300 mmHg or more A B Yes or more B A No 9 VACUUM TANK CHECK 1 Connect a hand vacuum pump to n...

Page 276: ...al steps 1 Vacuum hose connection 2 Air bypass valve assembly 3 Breather hose connection 4 Vacuum hose connection 5 Air intake hose assembly AA 6 Air bypass hose 7 Air hose connection AA 8 Air hose D...

Page 277: ...0 12 1 0 1 2 24 2 4 22 2 2 2 3 8 7 6 4 5 12 15 1 2 1 5 Removal steps 1 Control harness connection 2 Vacuum pipe hose assembly 3 Air pipe assembly AA 4 Gasket 5 Air hose 6 Air control valve 7 Engine ha...

Page 278: ...12 1 0 1 2 12 15 1 2 1 5 35 3 6 9 0 9 30 3 1 35 3 6 20 2 0 22 2 2 20 2 0 14 14 16 7 5 17 15 2 1 3 4 6 7 7 19 20 18 8 9 12 10 11 13 Removal steps 1 Center cover 2 Ignition coil connector connection 3 O...

Page 279: ...se being careful not to damage the O ring Caution Be careful not to let any engine oil get into the delivery pipe 2 Check to be sure that the high pressure hose turns smoothly If it does not turn smoo...

Page 280: ...9 0 9 12 15 1 2 1 5 2 3 4 29 3 0 20 49 59 5 0 6 0 54 64 5 5 6 5 30 3 1 17 20 1 7 2 0 10 1 0 42 4 2 10 1 0 10 12 1 0 1 2 17 1 7 49 5 0 27 32 2 7 3 3 19 6 10 12 10 11 18 7 8 9 17 16 15 14 13 5 Removal...

Page 281: ...sage holes in turbocharger INSTALLATION SERVICE POINTS AA TURBOCHARGER INSTALLATION 1 Clean the connections between oil pipe oil return pipe and water pipe Caution Ensure that no foreign matter will g...

Page 282: ...eck that there is no oil leak from the turbocharger 4 Check to see if the wastegate valve remains open If any of these faulty symptoms is evident disassemble the turbocharger and replace the defective...

Page 283: ...9 18 9 3 3 9 Main muffler removal steps 1 Bolt 2 Main muffler 3 Hanger Center exhaust pipe removal steps 1 Bolt 4 Spring 5 Heat protector 6 Self locking nut 7 Hanger bracket 8 Center exhaust pipe 9 H...

Page 284: ...TENTS CHARGING SYSTEM 2 ALTERNATOR 2 IGNITION SYSTEM 4 ON VEHICLE SERVICE 4 1 Ignition Coil with Built in Power Transistor Check 4 2 Spark Plug Check Cleaning and Replacement 4 CAMSHAFT POSITION SENSO...

Page 285: ...lation 2 Engine Mount Installation 3 Under Cover Installation 4 Drive Belt Tension Adjustment Refer to GROUP 11 On vehicle Service Unit Nm kgf m 44 4 5 7 3 2 6 1 5 4 24 2 4 22 2 2 9 0 9 12 15 1 2 1 5...

Page 286: ...the holes 2 Remove the drive belt AB DELIVERY PIPE INJECTOR AND PRESSURE REGULATOR ASSEMBLY REMOVAL After the mounting points have been loosened slightly move the corresponding part to allow for a sp...

Page 287: ...NT Check the plug gap and replace if the limit is exceeded Caution 1 Do not attempt to adjust the gap of the platinum plug 2 Cleaning the platinum plug can damage platinum tips If a cleaning is needed...

Page 288: ...9 4 0 3 0 3 2 3 4 1 Removal steps 1 Camshaft position sensor 2 Center cover AA 3 Power steering oil pump 4 Power steering oil pump bracket 5 Crank angle sensor REMOVAL SERVICE POINT AA POWER STEERING...

Page 289: ...SSION CONTROL CONTENTS ENGINE CONTROL SYSTEM 2 SERVICE SPECIFICATIONS 2 EMISSION CONTROL SYSTEM 2 ON VEHICLE SERVICE 2 System Configuration Diagram 2 Vacuum Hose Piping Circuit Diagram 3 CANISTER 3 CA...

Page 290: ...TEM SERVICE SPECIFICATIONS Items Standard value Idle speed rpm 850 50 EMISSION CONTROL SYSTEM MPI ON VEHICLE SERVICE SYSTEM CONFIGURATION DIAGRAM Canister Check valve Throttle body Fuel pressure contr...

Page 291: ...ck valve Throttle body Fuel pressure regulator Wastegate solenoid valve Secondary air valve Bypass valve Front of vehicle Wastegate actuator Vacuum hose color B Black L Blue R Red W White Y Yellow CAN...

Page 292: ...I 17 4 CATALYTIC CONVERTER REMOVAL AND INSTALLATION Unit Nm kgf m 3 2 1 5 4 49 5 0 5 0 5 19 1 9 49 5 0 49 5 0 34 3 5 13 1 3 Removal steps 1 Spring 2 Heat protector 3 Front exhaust pipe 4 High temperat...

Page 293: ...21 1 CLUTCH CONTENTS SERVICE SPECIFICATIONS 2 LUBRICANTS 2 ON VEHICLE SERVICE 2 1 Clutch Pedal Inspection and Adjustment 2 2 Bleeding 3 CLUTCH PEDAL 4 CLUTCH CONTROL 5 Clutch Master Cylinder 6...

Page 294: ...d MITSUBISHI genuine brake fluid DIA QUEEN BRAKE FLUID SUPER 4 As required Push rod assembly Rubber grease Boot Release cylinder push rod MOLYKOT BR 2 PUS ON VEHICLE SERVICE 1 CLUTCH PEDAL INSPECTION...

Page 295: ...e C 6 13 mm Standard value D 70 mm or more 7 If the clutch pedal free play and the distance between the clutch pedal and the toeboard when the clutch is disengaged do not agree with the standard value...

Page 296: ...ion 13 5 Unit Nm kgf m 13 1 3 1 13 4 11 12 2 7 6 8 9 10 6 3 5 24 2 4 13 1 3 12 1 2 Removal steps 1 Clutch master cylinder installation nut 2 Master cylinder member bracket installation bolt 3 Clevis p...

Page 297: ...l Adjustment Refer to P 21 2 Specified grease MOLYKOT BR 2 PLUS 5 Unit Nm kgf m 13 1 3 6 6 4 6 7 8 2 3 1 5 0 5 15 1 5 19 1 9 Release cylinder push rod Release fork Clutch master cylinder removal steps...

Page 298: ...lutch fluid DIA QUEEN BRAKE FLUID SUPER 4 Grease Rubber grease 5 2 2 1 4 2 2 8 3 Unit Nm kgf m 13 1 3 Disassembly steps 1 Piston stopper ring 2 Piston assembly 3 Push rod assembly 4 Boot 5 Reservoir c...

Page 299: ...MANUAL TRANSMISSION 22A MANUAL TRANSMISSION OVERHAUL 22B 22 1 MANUAL TRANSMISSION CONTENTS...

Page 300: ...22 2 NOTES...

Page 301: ...SEMBLY 7 TRANSFER ASSEMBLY 10 WARNING REGARDING SERVICING OF SUPPLEMENTAL RESTRAINT SYSTEM SRS EQUIPPED VEHICLES 1 Thoroughly review this manual especially GROUP 52B Supplemental Restraint System SRS...

Page 302: ...2 SPECIAL TOOLS Tool Number Name Use MB990635 or MB991113 Steering linkage puller Tie rod end and lower arm disconnection Recommended tool MZ203826 by Anzen Jidosha or MZ203827 by Banzai Engine lifter...

Page 303: ...2 8 4 Tighten the filler plug to the specified torque Tightening torque 32 Nm 3 3 kgf m 3 TRANSFER OIL CHECK 1 Remove the oil filler plug 2 Oil level should be at the lower portion of the filler plug...

Page 304: ...removal steps BA 1 Shift knob BA 2 Spring washer BA 3 Nut D Front floor console Refer to GROUP 52 4 Snap pin 5 Select cable connection Shift lever side 6 Clip 7 Shift cable connection Shift lever sid...

Page 305: ...s should face the snap pins 3 Move the shift lever to all positions and check that the operation is smooth BA NUT SPRING WASHER SHIFT KNOB INSTALLATION 1 Screw in the nut all the way by hand turn back...

Page 306: ...A 6 SHIFT LEVER ASSEMBLY DISASSEMBLY AND REASSEMBLY 1 2 3 4 5 7 8 9 10 3 9 6 Unit Nm kgf m 14 1 4 10 1 0 Disassembly steps 1 Bolt 2 Select lever 3 Bushing 4 Return spring 5 Collar 6 Bolt 7 Cap 8 Shift...

Page 307: ...r Installation 5 Transfer Oil Supplying Refer to P 22A 3 6 Transmission Oil Supplying Refer to P 22A 3 7 Shift Lever Operation Check 8 Speedometer Operation Check 1 2 3 4 5 6 7 8 8 Unit Nm kgf m 49 5...

Page 308: ...e rod end connection 13 Lower arm ball joint connection AA D Clutch release bearing connection 14 Centermember assembly AB 15 Drive shaft LH connection AB 16 Drive shaft RH connection D Strut assembly...

Page 309: ...ibly prying can cause the release bearing to be damaged AB DRIVE SHAFT LH DRIVE SHAFT RH DISCONNECTION 1 To disconnect the left hand drive shaft insert a lever as shown and pry out the shaft from the...

Page 310: ...l MITSUBISHI genuine Dia Queen Super hypoid gear oil GL 5 Unit Nm kgf m 2 69 7 0 1 Removal steps D Drive shaft Refer to P 22A 9 D Output shaft Refer to P 22A 9 1 Front propeller shaft Refer to GROUP 2...

Page 311: ...D ADHESIVES 5 LUBRICANTS 6 SNAP RINGS SPACERS AND THRUST PLATES FOR ADJUSTMENT 6 TORQUE SPECIFICATIONS 9 SPECIAL TOOLS 10 TRANSMISSION 13 INPUT SHAFT 20 OUTPUT SHAFT 27 REVERSE IDLER GEAR 35 SPEEDOMET...

Page 312: ...MANUAL TRANSMISSION OVERHAUL General Information 22B 2 GENERAL INFORMATION SECTIONAL VIEW Without Front Limited Slip Differential Front LSD...

Page 313: ...MANUAL TRANSMISSION OVERHAUL General Information 22B 3 SECTIONAL VIEW With Front Limited Slip Differential Front LSD...

Page 314: ...51 1 Z7A1 B 30 36 4 875 Available GEAR RATIO TABLE A B 1st 2 785 2nd 1 950 3rd 1 407 1 444 4th 1 031 1 096 5th 0 761 0 825 Reverse 3 416 Transfer gear ratio 0 3018 SERVICE SPECIFICATIONS Items Allowab...

Page 315: ...s however the sealant between the joined surfaces may have to be broken by lightly striking with a mallet or similar tool A flat and thin gasket scraper may be lightly hammered in between the joined s...

Page 316: ...ential oil seal lip area Transmission oil O rings SNAP RINGS SPACERS AND THRUST PLATES FOR ADJUSTMENT Part name Thickness mm Identification symbol Part No Spacer For adj stment of inp t shaft end pla...

Page 317: ...5 MD748468 3 98 6 MD748469 4 02 7 MD748470 4 06 8 MD748471 4 10 9 MD748472 Spacer For adj stment of o tp t shaft preload 0 86 86 MD720938 For adjustment of output shaft preload 0 89 89 MD720939 0 92 9...

Page 318: ...nap ring For adj stment of o tp t shaft 3rd speed gear 2 81 None MD746594 For adjustment of output shaft 3rd speed gear clearance 2 85 Blue MD746595 2 89 Brown MD746596 2 93 Yellow MD746597 2 97 Green...

Page 319: ...0 8 MD748364 0 9 MD748365 1 0 MD748366 1 1 MD748367 TORQUE SPECIFICATIONS TRANSMISSION Items Nm kgf m Under cover mounting bolt 6 9 0 7 Interlock plate bolt 30 3 1 Clutch housing transmission case mou...

Page 320: ...transfer oil seal MB990891 Bushing remover installer base Installation of transfer oil seal MB990928 Installer adapter Installation of input shaft oil seal MB990932 Installer adapter Removal of diffe...

Page 321: ...extension housing oil seal MD998364 Camshaft oil seal installer Installation of gear bearing and sleeve MD998800 Oil seal installer Installation of differential oil seal and transfer cover oil seal M...

Page 322: ...8821 Installer adapter 44 Installation of 4th speed gear 5th speed gear sleeve and 5th reverse speed synchronizer hub MD998824 Installer adapter 50 Installation of 1st 2nd speed synchronizer hub 2nd s...

Page 323: ...2 3 4 5 6 7 8 9 10 11 Unit Nm kgf m 18 1 9 69 7 0 69 7 0 18 1 9 69 7 0 3 9 0 4 32 3 3 32 3 3 3 Disassembly steps 1 Transfer JA 2 O ring 3 Roll stopper bracket 4 Insulator washer 5 Shift cable bracket...

Page 324: ...7 Unit Nm kgf m 18 1 9 30 3 1 48 4 9 3 9 0 7 44 4 5 Disassembly steps 12 Interlock plate bolt 13 Gasket GA 14 Control housing 15 Neutral return spring FA 16 Under cover 17 Reverse idler gear shaft bol...

Page 325: ...ly steps CA 28 Spring pin 29 1st 2nd speed shift rail 30 1st 2nd speed shift fork CA 31 Spring pin AA CA 32 Spring pin AB BA 33 3rd 4th speed shift rail AB BA 34 3rd 4th speed shift fork AB BA 35 5th...

Page 326: ...REMOVAL Remove the input shaft output shaft and center differential together ADJUSTMENT BEFORE REASSEMBLY SPACER SELECTION FOR ADJUSTING INPUT SHAFT END PLAY OUTPUT SHAFT PRELOAD DIFFERENTIAL PRELOAD...

Page 327: ...that will provide the standard end play preload value Standard value Input shaft end play 0 0 17 mm Output shaft end play 0 13 0 18 mm Center differential preload 0 05 0 11 mm REASSEMBLY SERVICE POIN...

Page 328: ...NSTALLATION Apply sealant to the illustrated position of the transmission case Specified sealant THREEBOND 1216 Caution Squeeze out the sealant uniformly while making sure that it is not broken or exc...

Page 329: ...mission oil to the O ring of the speedometer gear Transmission oil DIA QUEEN MULTI GEAR OIL 75W 85W IA SELECT LEVER INSTALLATION Apply grease to the control shaft sliding portion of the select lever s...

Page 330: ...KA 3 Thrust plate stopper JA 4 Thust plate AC IA 5 5th speed gear 6 4th speed gear 7 Needle roller bearing AD HA 8 4th speed gear sleeve 9 Synchronizer ring GA 10 Synchronizer spring FA 11 Synchroniz...

Page 331: ...PPER REMOVAL Using a screwdriver pry up the position shown in the illustration and remove the thrust plate stopper AC 5TH SPEED GEAR REMOVAL AD 4TH SPEED GEAR SLEEVE REMOVAL Install the special tool t...

Page 332: ...t shaft front bearing end play will have the standard value Standard value 0 0 12 mm DA SYNCHRONIZER SPRING INSTALLATION Install the synchronizer spring securely to the illustrated position of the out...

Page 333: ...direction shown 2 When the synchronizer sleeve is installed make sure that the deep groove portion of the synchronizer hub is aligned with the projecting portion of the sleeve GASYNCHRONIZER SPRING I...

Page 334: ...ced against the thrust plate stopper KA THRUST PLATE STOPPER INSTALLATION Install the thrust plate stopper by pressing the special tools with hand Make sure that the stopper is not installed aslant LA...

Page 335: ...nsure that the cage is not deformed SYNCHRONIZER RING 1 Check to ensure that the clutch gear tooth surfaces are not damaged and broken 2 Check to ensure that the cone inside surface is not damaged or...

Page 336: ...k to ensure that the front and rear ends of the sleeve inside surface are not damaged Caution When replacement of either the synchronizer sleeve or hub is necessary make sure that the synchronizer sle...

Page 337: ...se speed synchronizer hub 10 Synchronizer ring LA 11 Synchronizer spring 12 5th speed gear 13 Needle roller bearing KA 14 5th speed gear sleeve JA 15 4th speed gear IA 16 Snap ring AD HA 17 3rd speed...

Page 338: ...AL Mount a special tool on the 4th speed gear and remove the 5th reverse speed synchronizer hub AD 3RD SPEED GEAR REMOVAL Mount a special tool on the 2nd speed gear and remove the 3rd speed gear AE 2N...

Page 339: ...NSTALLATION Make sure that the oil seal is pressed into the position shown in the illustration BA TAPER ROLLER BEARING INSTALLATION CA 1ST SPEED GEAR SLEEVE INSTALLATION 1st speed gear sleeve MD998801...

Page 340: ...caught FA SYNCHRONIZER SLEEVE INSTALLATION 1 Install the synchronizer sleeve in such a way that it will be oriented in the direction shown 2 When the synchronizer sleeve is installed make sure that th...

Page 341: ...utput shaft 3rd speed gear clearance will have the standard value Standard value 0 0 09 mm JA 4TH SPEED GEAR INSTALLATION KA 5TH SPEED GEAR SLEEVE INSTALLATION 2nd speed gear sleeve MD998364 MD998824...

Page 342: ...shown Caution When the hub is installed make sure that the synchronizer ring is not caught NA REVERSE GEAR NEEDLE ROLLER BEARING REVERSE GEAR BEARING SLEEVE INSTALLATION OATAPER ROLLER BEARING INSTAL...

Page 343: ...that when the bearing sleeve and gear are combined and made to rotate they rotate smoothly without looseness and noise 2 Check the cage for deformation SYNCHRONIZER RING 1 Check to ensure that the clu...

Page 344: ...and made to slide they slide smoothly without binding 2 Check to ensure that the front and rear ends of the sleeve inside surface are not damaged Caution When replacement of either the synchronizer s...

Page 345: ...ation 5 4 3 2 1 TFM0807 Disassembly steps 1 Snap ring 2 Thrust washer 3 Reverse idler gear 4 Needle roller bearing 5 Reverse idler gear shaft INSPECTION NEEDLE ROLLER BEARING 1 Check to ensure that wh...

Page 346: ...OVERHAUL Speedometer Gear 22B 36 SPEEDOMETER GEAR DISASSEMBLY AND REASSEMBLY Apply gear oil to all moving parts before installation 4 3 2 1 TFM0593 Disassembly steps 1 e clip 2 Speedometer driven gea...

Page 347: ...10 9 8 7 6 5 4 3 2 1 Unit Nm kgf m 11 1 2 Disassembly steps AA 1 Dust cover 2 Nut 3 Spring washer 4 Washer 5 Select lever bushing 6 Select lever shoe 7 Select lever 8 Select lever bushing AA 9 Dust co...

Page 348: ...kgf m 18 1 9 Disassembly steps AA FA 1 Lock pin 2 Interlock plate 3 Control finger 4 Pin 5 Return spring 6 Stopper plate EA 7 Spring pin DA 8 Spring pin 9 Stopper body 10 Neutral return spring 11 Spac...

Page 349: ...ng sure that the model number stamped side is oriented in the direction shown BA OIL SEAL INSTALLATION Apply transmission oil to the oil seal lip area Transmission oil DIA QUEEN MULTI GEAR OIL 75W 85W...

Page 350: ...40 DA SPRING PIN INSTALLATION EA SPRING PIN INSTALLATION FA LOCK PIN INSTALLATION Drive in the lock pin in the direction shown in the illustration Control shaft Stopper body Installation direction Sl...

Page 351: ...1 0 Unit Nm kgf m Disassembly steps 1 Clutch release bearing retainer EA 2 Oil seal AA DA 3 Outer race AB CA 4 Outer race BA 5 Bushing AA 6 Cover A AA 7 Cover B 8 Clutch housing NOTE Never remove the...

Page 352: ...NTS AA COVER A COVER B INSTALLATION Install the covers directed as shown in the illustration BA BUSHING INSTALLATION Press fit the bushing to the illustrated position while making sure that the split...

Page 353: ...ng 22B 43 CA OUTER RACE INSTALLATION DA OUTER RACE INSTALLATION EA OIL SEAL INSTALLATION Apply transmission oil to the oil seal lip area Transmission oil DIA QUEEN MULTI GEAR OIL 75W 85W MB990935 MB99...

Page 354: ...LY AND REASSEMBLY 4 3 2 1 Disassembly steps CA 1 Oil seal BA 2 Needle bearing AA 3 Bushing 4 Transmission case NOTE Never remove the bearing and bushing from the transmission case Only the case when i...

Page 355: ...ide with the air purge groove BA NEEDLE BEARING INSTALLATION Press fit the needle bearing until it is flush with the case while making sure that the model number stamped side is oriented in the direct...

Page 356: ...differential drive gear CA 2 Center differential flange AA BA 3 Taper roller bearing CA 4 Snap ring CA 5 Front output shaft CA 6 Spacer CA 7 Side gear CA 8 Lock pin CA 9 Pinion shaft CA 10 Pinion sha...

Page 357: ...PINION SHAFT LOCK PIN FRONT OUTPUT SHAFT SNAP RING CENTER DIFFERENTIAL FLANGE INSTALLATION 1 Install the side gear in the center differential case with the spacer attached NOTE If a new side gear is...

Page 358: ...ning the mating marks then secure it temporarily with machine screw 8 Measure the backlash between the side gear and the pinion Standard value 0 025 0 150 mm 9 If the measurement deviates from the sta...

Page 359: ...LY 10 2 11 4 8 7 9 5 3 1 6 Apply gear oil to all moving parts before installation 23 2 4 Unit Nm kgf m Disassembly steps FA 1 Air breather 2 Dust seal guard EA 3 Oil seal DA 4 Oil seal AA 5 O ring AA...

Page 360: ...L INSTALLATION 1 Apply transmission oil to the oil seal lip area Transmission oil DIA QUEEN MULTI GEAR OIL 75W 85W 2 By using the special tool install the oil seal DA OIL SEAL INSTALLATION 1 Apply tra...

Page 361: ...MANUAL TRANSMISSION OVERHAUL Transfer 22B 51 FA AIR BREATHER INSTALLATION Apply sealant to the air breather Specified sealant THREEBOND 1501...

Page 362: ...26 1 FRONT AXLE CONTENTS SERVICE SPECIFICATIONS 2 SPECIAL TOOLS 2 AXLE HUB AND KNUCKLE 3...

Page 363: ...B990767 End holder Fixing of hub MB991354 Puller body Removal of drive shaft A B MB990241 A MB990242 B MB990244 Axle shaft puller A Puller shaft B Puller bar A MB991017 B MB990998 C MB991000 A B Front...

Page 364: ...icles with AYC AA 2 Caliper assembly 3 Brake disc 4 Split pin AB AA 5 Drive shaft nut 6 Front hub assembly 7 Dust shield 8 Connection for lower arm ball joint 9 Split pin AC 10 Connection for tie rod...

Page 365: ...ll joint 2 Tie the special tool with a cord not to let it fall off AD DRIVE SHAFT REMOVAL INSTALLATION SERVICE POINT AA DRIVE SHAFT NUT INSTALLATION 1 Install the drive shaft washer in the specified d...

Page 366: ...mit value range and there should be no engagement or feeling of roughness 2 HUB AXIAL PLAY CHECK 1 Measure the hub play in the axial direction Limit 0 05 mm NOTE Measure the hub play while clamping th...

Page 367: ...g 29 6 Differential Carrier Oil Seal Replacement 30 7 Speed Sensor Output Voltage Measurement Vehicles without ABS 31 8 Action When Battery Runs Out 32 REAR HUB ASSEMBLY 33 KNUCKLE 35 DRIVE SHAFT 36 D...

Page 368: ...5 1 9 Nm kgf m When existing clutch plate is installed 2 19 0 2 1 9 Distortion of friction plate and friction disc mm 0 08 Difference in thickness between friction plate friction disc and spring plate...

Page 369: ...pressure measurement vehicles with AYC MB991705 Hose adapter MB990925 Bearing oil seal installer set Pressfitting of oil seal differential MB991115 Oil seal installer Pressfitting of oil seal differen...

Page 370: ...surement of wheel bearing axial play Use MB991000 component of MB990998 for the spacer MB990326 Preload socket D Measurement of wheel bearing rotation starting torque D Measurement of drive pinion pre...

Page 371: ...B MB990938 MB990932 61 0 C MB990939 TROUBLESHOOTING AYC 1 BASIC TROUBLESHOOTING CONDITIONS Before starting the troubleshooting procedure make sure that the following items have been checked okay D Th...

Page 372: ...sensor ST N system short circuit 27 11 33 Steer sensor ST N system 27 12 34 Steer sensor ST 1 ST 2 system short circuit 27 12 41 TPS system open or short circuit 27 13 51 Longitudinal acceleration se...

Page 373: ...h IG2 and AYC ECU OK Replace AYC ECU NG Repair Code No 21 22 23 24 Wheel speed sensor system Probable cause This code is output if any one of three wheel speed sensors fails to provide an input even a...

Page 374: ...symptom OK Check the following connectors B 95 B 52 B 17 A 26 A 50 D 04 D 14 D 19 NG Repair OK Measureat B 95 AYC ECUconnector D Disconnect the connector and measure at the harness side D Resistanceac...

Page 375: ...ector and measure at the harness side D Ignition switch OK D Turn tire at 1 2 to 1 revolution sec D Voltage across 6 7 8 9 and body ground OK 42 mV or more when mea sured with a circuit tester 120 mV...

Page 376: ...the connector and measure at the harness side D Ignition switch ON D Turn tire at 1 2 to 1 revolution sec D Voltage across 6 7 8 9 and body ground OK 42 mV or more when mea sured with a circuit tester...

Page 377: ...n the steering wheel is turned OK Check the following connector B 95 NG Repair NG Voltage alternates between 4 V or more and 0 5 V NG Voltage remains at 0 V Code No 32 Steer sensor ST N system Probabl...

Page 378: ...m about 0 5 V or less to about 3 5 V NG Check the following connectors B 95 B 65 B 98 NG Repair Code No 34 Steer sensor ST 1 ST 2 system Probable cause This code is output if a turning condition is de...

Page 379: ...D Defective AYC ECU NG Replace the acceleration sensor OK Check the trouble symptom OK Checkand repairtheharnessbetween acceleration sensor and ignition switch OK Check the trouble symptom NG Checkand...

Page 380: ...und OK 2 4V to 2 6 V where vehicle in horizontal position NG Check the following connectors B 95 B 52 D 20 Check the acceleration sensor Refer to P 27 52 NG Replace NG Repair Code No 61 Stop lamp swit...

Page 381: ...soutputwhentheproportioningvalvecontrolcircuitisopen orshort circuited D Defective proportioning valve D Defective harness or connector D Defective AYC ECU OK Checkand repairtheharnessbetween proporti...

Page 382: ...ECU NG Checktheharnessbetweendirectional control valve right and AYC ECU NG Repair OK Check the trouble symptom OK Check the following connectors B 96 B 94 D 06 F 30 F 29 NG Repair OK Measure at F 29...

Page 383: ...U NG Checktheharnessbetweendirectional control valve left and AYC ECU NG Repair OK Check the trouble symptom OK Check the following connectors B 96 B 94 D 06 F 30 F 28 NG Repair OK Measure at F 28 dir...

Page 384: ...AYC relay and body ground OK Check the trouble symptom OK Replace AYC ECU NG ChecktheharnessbetweenAYCrelay and AYC ECU NG Repair NG Check the trouble symptom OK Check the following connectors B 96 B...

Page 385: ...between fusible link no 10 and AYC relay OK Check the trouble symp tom OK Replacethe hydraulicunit for a defective accumula tor pressure switch NO Repair the leak OK Check the trouble symptom NG Chec...

Page 386: ...tch connector D Disconnect the connector and measure at the harness side D Ignition switch ON 1 Voltage across 2 and body ground OK Battery voltage 2 Continuity across 1 and body ground OK Conducting...

Page 387: ...cuit between AYC warning lamp and AYC ECU or AYC ECU itself is defective D Blown fuse D AYC warning lamp out D Defective harness or connector D Defective AYC ECU NG Checkand repairtheharnessbetween ig...

Page 388: ...ive Unable to start or accelerate on slippery road surfaces Probable cause The hydraulic oil level is probably low there is an oil leak the hydraulic unit is defective or the torque transfer different...

Page 389: ...nsfer differential NOTE This symptom is limited only when the diagnosis code is correct NG Replace the hydraulic unit NG Replacethetorquetransferdifferential Check the trouble symptom NG Replace AYC f...

Page 390: ...teer sensor ST 1 Engine Idle speed Turn steering wheel slowly 0 V approx 3 V flashing 6 1 FR wheel speed Vehicle stationary 1 V or less Forward vehicle slowly 0 5 V 7 1 FL wheel speed Vehicle stationa...

Page 391: ...31 AYC ECU power supply Ignition switch ON Battery voltage Ignition switch OFF 0 V 35 AYC motor relay Ignition switch ON When motor is energized Battery voltage ON When motor is deenergized 2 V or les...

Page 392: ...No Signal name Normally 2 body ground Longitudinal acceleration sensor ground lateral acceleration sensor ground Conducting 26 body ground ECU ground Conducting 35 body ground AYC motor relay Conduct...

Page 393: ...urn the propeller shaft fully counterclockwise and measure the deviation between the alignment marks Limit 5 mm 4 If the backlash exceeds the limit replace the differential carrier assembly 2 GEAR OIL...

Page 394: ...ug and tighten it to the specified torque 3 GEAR OIL CHANGE 3 1 DIFFERENTIAL 1 Remove the drain plug to discharge the gear oil 2 Fit the drain plug and tighten it to the specified torque Tightening to...

Page 395: ...AX and MIN 4 If the fluid level is lower than MIN add the specified fluid Specified fluid MITSUBISHI DIA QUEEN ATF SPII 5 Reinstall the maintenance lid 5 BLEEDING 1 Lift up the vehicle 2 Remove the ca...

Page 396: ...ose grease 5 Replace the drive shaft circlip with a new one and mount the drive shaft to the differential carrier Refer to P 27 36 6 Check for correct wheel alignment Refer to GROUP 34 On vehicle Serv...

Page 397: ...pe is used 200 mVp p or more 4 If the output voltage is lower than the above value it is probably attributable to the following faults Check or replace the speed sensor as necessary D Excessive cleara...

Page 398: ...uspension it may be open circuited only when the vehicle is run on rough roads and not on ordinary road The speed sensor output voltage waveform should therefore be checked also by rocking the sensor...

Page 399: ...ection AB AA 6 Drive shaft nut AC 7 Rear hub assembly 8 Backing plate Caution Do not disassemble the rear hub assembly REMOVAL SERVICE POINTS AA CALIPER ASSEMBLY REMOVAL Secure the removed caliper ass...

Page 400: ...EL BEARING ROTATION STARTING TORQUE 1 Install the special tool to the rear hub assembly and tighten it to the specified torque 2 Using the special tool measure the wheel bearing rotation starting torq...

Page 401: ...Removal steps 1 Rear speed sensor connection Vehicles with AYC AA 2 Trailing arm connection 3 Lower arm connection AA 4 Toe control arm connection AA 5 Upper arm connection 6 Knuckle Caution Indicates...

Page 402: ...ehicle Service 1 2 3 4 5 6 7 8 9 10 11 Unit Nm kgf m 25 2 6 74 87 7 5 8 9 74 87 7 5 8 9 88 9 0 49 59 5 0 6 0 196 255 20 0 26 0 Removal steps 1 Caliper assembly Refer to P 27 33 2 Brake disc 3 Shoe lin...

Page 403: ...r Caution 1 Be sure to remove the drive shaft from the differential side using a lever Removing it from the BJ side could damage the parts 2 Do not apply the vehicle weight to the wheel bearing with t...

Page 404: ...drive shaft in the direction shown on the left 2 Using the special tool tighten the drive shaft nut to the specified torque Caution Before torquing the drive shaft nut to specification do not apply ve...

Page 405: ...stallation Refer to GROUP 34 3 Lower Arm Assembly Installation Refer to GROUP 35 4 Gear Oil Filling Refer to P 27 28 5 Hydraulic Piping Fluid Filling and Bleeding Refer to P 27 29 1 2 3 4 5 6 7 8 9 10...

Page 406: ...r shown NOTE To ensure both good installation accuracy and ease of installation the rear crossmember mounting holes have different diameters between front and rear This is the reason for specifying th...

Page 407: ...Installation 4 Differential Gear Oil Filling 1 2 3 4 5 6 7 8 9 10 Unit Nm kgf m 29 34 3 0 3 5 88 9 0 108 127 11 0 13 0 3 6 9 7 2 108 127 11 0 13 0 108 127 11 0 13 0 88 9 0 88 9 0 88 9 0 69 7 0 108 12...

Page 408: ...INSTALLATION SERVICE POINTS AA REAR CROSSMEMBER AND DIFFERENTIAL CARRIER ASSEMBLY INSTALLATION Tighten the rear crossmember mounting bolts in the numerical order shown NOTE To ensure both good install...

Page 409: ...0 9 9 0 9 49 5 0 3 Disassembly steps 1 Drain plug 2 Packing 3 Filler plug 4 Gasket 5 Vent plug 6 Bleeder screw 7 Cover AA 8 Self locking nut 9 Washer 10 Companion flange 11 Oil seal BA 12 Oil seal AA...

Page 410: ...REAR AXLE Torque Transfer Differential Vehicles with AYC 27 44 GREASE AND SEALANT APPLICATION POINTS Grease Vaseline Semi drying sealant THREEBOND 1281B Semi drying sealant THREEBOND 1281B 3 0 mm...

Page 411: ...NSTALLATION 1 Using the special tool pressfit the oil seal as far as it will go 2 Apply the specified grease to the oil seal lip Specified grease Vaseline BA OIL SEAL INSTALLATION 1 Using the special...

Page 412: ...plate 9 Pressure ring 10 Side gear 11 Pinion gear 12 Pinion shaft 13 Pressure ring 14 Friction plate 15 Friction disc 16 Friction plate 17 Friction disc 18 Friction plate 19 Spring plate AA 20 Differe...

Page 413: ...nd left spring plates 3 Assemble the pressure ring internal parts pinion shaft and pressure ring friction plates and friction discs and using a micrometer measure the overall width NOTE When taking me...

Page 414: ...the specified range disassemble the differential case assembly and repair or replace defective parts INSPECTION 1 DIFFERENTIAL CASE INTERNAL PARTS CONTACT SLIDING SURFACE CHECK 1 Clean the disassembl...

Page 415: ...re ring hole and side gear H Protrusions on outer periphery of pressure ring I Pressure ring inner surface and differential pinion gear spherical surface J Pressure ring V groove and pinion shaft V K...

Page 416: ...12 1 2 12 1 2 18 1 8 34 3 5 34 3 5 Removal steps 1 Dust guard 2 Suction hose and return hose con nection 3 Hydraulic unit hose assembly con nection 4 Hydraulic unit and bracket assem bly mounting bol...

Page 417: ...ON HOSE RETURN HOSE INSTALLATION Fit the suction hose and return hose to the nipple of hydraulic unit as illustrated CA HYDRAULIC UNIT AND BRACKET ASSEMBLY INSTALLATION Hook the hydraulic unit bracket...

Page 418: ...and AYC relay removal 2 Longitudinal acceleration sensor 3 Lateral acceleration sensor 4 AYC relay NOTE For the wheel speed sensor refer to GROUP 35B REMOVAL SERVICE POINT AA STEER SENSOR REMOVAL Remo...

Page 419: ...ENSOR CHECK Refer to GROUP 35B Acceleration Sensor 2 AYC RELAY CONTINUITY CHECK Battery voltage Terminal No 1 3 4 5 When not energized When energized AYC ECU REMOVAL AND INSTALLATION Pre removal and P...

Page 420: ...ROLL STOPPER AND CENTERMEMBER 2 32 1 POWER PLANT MOUNT CONTENTS...

Page 421: ...n torque to specification with the engine weight applied to the body 1 2 3 4 5 Unit Nm kgf m 52 5 3 2 2 34 3 5 34 3 5 93 9 5 69 7 0 93 9 5 2 Removal steps 1 Front crossmember bar vehicles with 17 whee...

Page 422: ...SPENSION CONTENTS SERVICE SPECIFICATIONS 2 SPECIAL TOOLS 2 ON VEHICLE SERVICE 3 Wheel Alignment Check and Adjustment EVOLUTION V 3 STRUT ASSEMBLY 4 LOWER ARM EVOLUTION IV 5 LOWER ARM EVOLUTION V 7 STA...

Page 423: ...tion starting torque Nm kgf cm 2 0 8 8 20 90 EVOLUTION V Same as EVOLUTION IV except for following Items Standard value Camber selectable from 2 options 1_00 30 or 2_00 30 difference between right and...

Page 424: ...wheel less than 30 Select the camber angle as follows If the arrow on the bolt that couples the strut assembly to knuckle faces inboard 1_00 30 If the arrow on the bolt that couples the strut assembl...

Page 425: ...o P 33A 3 1 2 3 4 5 6 7 Unit Nm kgf m 44 4 5 108 127 11 0 13 0 Removal steps 1 Brake hose clamp 2 Front speed sensor bracket Vehicles with ABS 3 Flange nut 4 Strut tower bar 5 Plain washer AA 6 Bolts...

Page 426: ...113 11 5 Molybdenum disulfide base chassis grease SHOWA SHELL SEKIYU SUNLITE MB2 NISSEKI CLAKNOCK FL or equivalent 137 14 0 88 9 0 106 10 8 6 Removal steps 1 Stabilizer link mounting nut AA 2 Lower a...

Page 427: ...BALL JOINT ROTATION STARTING TORQUE Use the conventional procedures except the special tool used and the standard value as given below Standard value 2 0 8 8 Nm 20 90 kgf cm LOWER ARM BALL JOINT DUST...

Page 428: ...rm and Stabilizer Link Ball Joint with a Finger to Check for Possible Cracks or Damage 2 Wheel Alignment Check and Adjustment Refer to P 33A 3 1 2 3 4 5 6 Unit Nm kgf m Molybdenum disulfide base chass...

Page 429: ...tion of the lower arm assembly 2 Should the knuckle be pushed in excessively and grease flow out from the dust cover replace the dust cover with a new one 3 Check that there is no clearance between th...

Page 430: ...er 1 2 3 4 5 Unit Nm kgf m 22 2 2 SHOWA SHELL SEKIYU VARIANT R 2 or equivalent 39 4 0 39 4 0 1 Removal steps 1 Stabilizer link 2 Stabilizer bar bracket AA 3 Fixture AA 4 Bushing 5 Stabilizer bar INSTA...

Page 431: ...llow the conventional procedures STABILIZER LINK DUST COVER REPLACEMENT Replace the dust cover by using the conventional procedure only if it has been inadvertently damaged during servicing After the...

Page 432: ...IAL TOOLS 2 ON VEHICLE SERVICE 3 1 Rear Wheel Alignment Check and Adjustment 3 2 Ball Joint Dust Cover Check 3 REAR SUSPENSION ASSEMBLY 4 UPPER ARM ASSEMBLY 6 TRAILING ARM ASSEMBLY 8 LOWER ARM AND TOE...

Page 433: ...arm ball joint dust cover Molybdenum disulfide base chassis grease SHOWA SHELL SEKIYU SUNLITE MB2 As required Inside and lips of trailing arm ball joint dust cover SHOWA SHELL SEKIYU SUNLITE MB2 NISSE...

Page 434: ...he camber adjusting bolt mounting bolt for the lower arm and rear crossmember Left wheel clockwise camber Right wheel clockwise camber The scale has gradations of approximately 14 2 After adjusting th...

Page 435: ...5 108 127 11 0 13 0 54 5 5 88 9 0 93 9 5 88 9 0 15 8 2 15 29 34 3 0 3 5 25 2 6 34 3 5 25 2 5 69 7 0 Toe control bar EVOLUTION V RS 137 156 14 0 16 0 59 68 6 0 7 0 Removal steps 1 Fuel filler cap 2 Bol...

Page 436: ...MOUNTING BOLT INSTALLATION Tighten the mounting bolts in the numerical order shown NOTE To ensure both good installation accuracy and ease of installation the crossmember mounting holes have differen...

Page 437: ...bly to knuckle coupling 5 Upper arm assembly mounting bolt 6 Stopper 7 Upper arm assembly NOTE Parts marked with K apply only when RH side is removed and installed Caution The part marked with should...

Page 438: ...t cover for cracks or damage by pushing it with a finger 2 If the dust cover is cracked or damaged replace the upper arm assembly NOTE A cracked or damaged dust cover can lead to a damaged ball joint...

Page 439: ...2 Trailing arm assembly to knuckle coupling 3 Trailing arm assembly mounting bolt 4 Stopper 5 Trailing arm assembly Caution The part marked with should be first temporarily tightened then torqued to s...

Page 440: ...cover for cracks or damage by pushing it with a finger 2 If the dust cover is cracked or damaged replace the trailing arm assembly NOTE A cracked or damaged dust cover can lead to a damaged ball join...

Page 441: ...0 93 9 5 2 Lower arm assembly removal steps 1 Lower arm assembly and shock absorber connecting bolt AA 2 Lower arm assembly mounting bolt AA 3 Lower arm assembly Toe control arm assembly removal step...

Page 442: ...ording to the identification mark stamped in the illustrated position INSPECTION 1 TOE CONTROL ARM BALL JOINT TURNING TORQUE CHECK 1 After shaking the ball joint stud several times install the nut to...

Page 443: ...continued use 3 TOE CONTROL ARM BALL JOINT DUST COVER CHECK 1 Check the dust cover for cracks or damage by pushing it with a finger 2 If the dust cover is cracked or damaged replace the toe control a...

Page 444: ...peration D Trunk Room Side Trim Removal and Installation GSR 1 2 3 4 Unit Nm kgf m 44 4 5 88 9 0 Removal steps 1 Cap 2 Shock absorber mounting nuts 3 Bolt 4 Shock absorber assembly Caution The part ma...

Page 445: ...tion Operation D Check the Stabilizer Link Ball Joint Dust Cover for Cracks or Damage by Pushing it with Finger 1 2 3 4 5 Unit Nm kgf m 39 4 0 3 39 4 0 39 4 0 20 2 0 Removal steps 1 Stabilizer link mo...

Page 446: ...l tool to measure the turning torque of the ball joint Standard value 1 7 3 1 Nm 17 32 kgf cm 2 When the measured value exceeds the standard value replace the stabilizer link 3 When the measured value...

Page 447: ...f the dust cover Specified grease SHOWA SHELL SEKIYU VARIANT R 2 or equivalent 3 Wrap plastic tape on the stabilizer link threads as shown in the illustration and then install the dust cover to the st...

Page 448: ...BASIC BRAKE SYSTEM 35A ANTI LOCK BRAKING SYSTEM ABS 35B 35 1 SERVICE BRAKES CONTENTS...

Page 449: ...35 2 NOTES...

Page 450: ...rake Booster Operation Check 3 2 Proportioning Valve Function Test 3 3 Bleeding EVOLUTION V 4 4 Disc Brake Pad Check and Replacement EVOLUTION IV 4 5 Disc Brake Pad Check and Replacement EVOLUTION V 4...

Page 451: ...a kgf cm2 input fluid pressure kPa kgf cm2 4 658 47 5 9 807 100 Front disc brake drag force N kgf 51 5 2 Rear disc brake Brake pad thickness mm 10 0 2 0 Brake disc thickness mm 20 0 18 4 Brake drag fo...

Page 452: ...CHECK The conventional procedures apply except for the following standard value Nonboosting action test Standard value Fluid pressure generated kPa kgf cm2 Pedal force 98 N 10 kgf 49 0 5 or more Pedal...

Page 453: ...procedures apply except for the following standard value for the brake pad thickness Standard value brake pad thickness 10 0 mm Limit 2 0 mm 5 DISC BRAKE PAD CHECK AND REPLACEMENT EVOLUTION V NOTE Th...

Page 454: ...se will not be applied to any other surfaces 9 Mount the pad to the caliper so that its side with the wear indicator is on the outside of the vehicle With the rear pad ensure that the arrow on the pad...

Page 455: ...a wire 2 Remove the brake disc 3 Measure the I D of the brake drum at 2 places or more Standard value 168 0 mm Limit 169 0 mm 4 If the brake drum I D has worn to exceed the limit or if an excessive ec...

Page 456: ...standard value for the disc brake drag force Standard value disc brake drag force 51 N 5 2 kgf EVOLUTION IV 69 N 7 0 kgf EVOLUTION V DISASSEMBLY AND REASSEMBLY NOTE On EVOLUTION IV follow the same pr...

Page 457: ...Unit Nm kgf m 29 3 0 49 59 5 0 6 0 Removal steps 1 Brake hose connection 2 Gasket AA 3 Rear brake assembly 4 Brake disc NOTE Shown here is the illustration of rear brake for EVOLUTION IV INSTALLATION...

Page 458: ...al boot kit Brake caliper kit 14 7 8 0 8 5 14 14 12 12 14 14 11 11 13 13 3 9 7 5 5 6 2 1 3 5 8 7 6 4 5 9 Disassembly steps AA 1 Lock pin AA 2 Guide pin 3 Bushing 4 Caliper support pad clip shim 5 Pin...

Page 459: ...LICATION POINTS Caution Do not wipe the piston seal in the seal boot kit clean of the special grease applied to it Brake fluid MITSUBISHI GENUINE DIA QUEEN BRAKE FLUID SUPER 4 Grease Repair kit grease...

Page 460: ...r inner surface with trichloroethylene alcohol or the specified brake fluid Brake fluid MITSUBISHI GENUINE DIA QUEEN BRAKE FLUID SUPER 4 INSTALLATION SERVICE POINT AA LOCK PIN GUIDE PIN INSTALLATION I...

Page 461: ...12 DISASSEMBLY AND REASSEMBLY EVOLUTION V 1 2 3 4 5 6 7 8 Grease Repair kit grease 4 5 Disassembly steps 1 Clip 2 Pin 3 Cross spring 4 Pad wear indicator assembly 5 Pad assembly 6 Air bleeder screw 7...

Page 462: ...spection Procedure for Diagnostic Trouble Codes 3 3 Inspection Chart for Trouble Symptoms 11 4 Inspection Procedure for Trouble Symptoms 12 5 Check at ABS ECU Terminals 15 ON VEHICLE SERVICE 17 Wheel...

Page 463: ...35B 3 14 Wheel speed sensor RL system open or short circuit 35B 3 15 Wheel speed sensor system abnormal output signal 35B 4 16 ABS ECU power supply voltage system abnormal voltage drop or rise 35B 5 2...

Page 464: ...ing sensor or a warped ABS rotor is causing sensor output to drop D Malfunction of wheel speed sensor D Malfunction of wiring harness or connector D Too much gap between the sensor and the rotor D Mal...

Page 465: ...connector D Malfunction of ABS ECU D Malfunction of wheel bearing OK Check the harness wire and repair if necessary D Betweeneachwheelspeedsensor and ABS ECU OK Wheel bearing check NG Replace the ABS...

Page 466: ...motor relay NG Repair OK NG Check the harness wire and repair if necessary D BetweenvalverelayandABS ECU NG Repair OK Check the trouble symptom OK Check the trouble symptom NG Check the harness wire a...

Page 467: ...D Defective ABS ECU OK Check the trouble symptom NG Replace ABS ECU OK Check the trouble symptom NG Checkandrepairtheharnessbetween acceleration sensor longitudinal acceleration and ABS ECU OK Check t...

Page 468: ...turn on and off normally NO Stop lamp switch installation check NG Repair Code No 41 42 43 44 Solenoid valve system Probable cause ABS ECU monitors the solenoid valve energization circuit at all time...

Page 469: ...d and if no diagnosis code other than No 51 is output then the valve relay system is probably defective Make the following checks OK Check the trouble symptom NG Checkandrepairtheharnessbetween genera...

Page 470: ...y OK Check the trouble symptom NG Checkandrepairtheharnessbetween motor relay and hydraulic unit OK Check the trouble symptom NG Checkandrepairtheharnessbetween motor relay and ABS ECU motor monitor t...

Page 471: ...se No 6 and acceleration sensor lateral accelera tion OK Replace ABS ECU OK Check the following connector B 24 NG Repair OK Measureat B 24 ABS ECU connector D Connect the connector D Ignition switch O...

Page 472: ...ce and then switches off 3 35B 13 When the ignition key is turned to START the ABS warning lamp does not illuminate 4 35B 14 Brake operation is abnormal 5 35B 14 Caution 1 If steering movements are ma...

Page 473: ...epair OK Check the trouble symptom NG Check the harness wire and repair if necessary D Between ignition switch and ABS warning lamp OK Check the motor for operation NG Check the harness wire and repai...

Page 474: ...ation meter INSPECTION PROCEDURE 3 After the ignition key is turned to ON the ABS warning lamp blinks once and when turned to START it illuminates When returned to ON the lamp flashes once and then sw...

Page 475: ...easureatvalverelayconnectorA 76 D Disconnect the connector and measure at the harness side D Disconnect ABS ECU connector B 25 D Ignition switch ON D Voltage between 3 and body ground OK Battery volta...

Page 476: ...tput Ignition switch ON after initial check Battery voltage 15 Ground At all times 0 V 17 Acceleration sensor ground At all times 0 V 18 Acceleration sensor lateral acceleration input Ignition switch...

Page 477: ...FF position and ABS ECU connector disconnected 2 Measure the resistance and check for continuity across terminals listed below 3 Fig below shows the arrangement of terminals Terminal No Signal name No...

Page 478: ...sure the output voltage of the wheel speed sensors are different from EVOLUTION V Follow the conventional procedures except these pick out terminals Measurement terminals Front LH Front RH Rear LH Rea...

Page 479: ...sensor 2 Front rotor Refer to GROUP 26 DRIVE SHAFT Rear speed sensor removal steps 3 Rear speed sensor 4 Rear rotor Refer to GROUP 27 REAR AXLE HUB NOTE The front rotor and rear rotor are integrated w...

Page 480: ...NG BRAKES CONTENTS SERVICE SPECIFICATIONS 2 LUBRICANTS 2 SPECIAL TOOLS 2 ON VEHICLE SERVICE 3 1 Parking Brake Lever Stroke Check and Adjustment 3 2 Lining Running in 4 PARKING BRAKE CABLE 5 PARKING BR...

Page 481: ...ption is made only for EVOLUTION IV SERVICE SPECIFICATIONS Items Standard value Limit Parking brake lever stroke operating force approx 196 N 20 kgf 5 7 notches Brake lining thickness mm 2 8 1 0 Brake...

Page 482: ...by both hands Return the adjuster five notches in the direction opposite to the direction of the arrow Reference shoe clearance on one side 0 19 mm 3 Turn the adjusting nut to adjust the parking brak...

Page 483: ...afety 1 Adjust the parking brake stroke to the specified value Standard value 5 7 notches Operating force of approx 196 N 20 kgf 2 Hook a spring balance onto the center of the parking brake lever grip...

Page 484: ...Console and Rear Seat Installation 1 2 3 4 5 6 7 8 9 10 11 12 13 Unit Nm kgf m 49 59 5 0 6 0 Backing plate Brake grease CHUO YUKA AKB100 10 11 9 8 11 11 5 Removal steps AA 1 Rear brake caliper assemb...

Page 485: ...so that the shoe adjusting bolt of left hand wheel is attached towards the front of the vehicle and the shoe adjusting bolt of right hand wheel is towards the rear of the vehicle BA SHOE TO ANCHOR SP...

Page 486: ...se CHUO YUKA AKB100 11 11 5 196 255 20 0 26 0 11 9 8 74 88 7 5 9 0 17 Removal steps 1 Rear brake caliper Refer to P 36 6 2 Rear brake disc 3 Shoe to anchor spring Refer to P 36 6 4 Adjusting screw spr...

Page 487: ...ng removal and tighten the drive shaft nut to the specified torque Tightening torque 196 255 Nm 20 0 26 0 kgf m INSPECTION BRAKE LINING AND BRAKE DRUM WEAR CHECK 1 Measure the thickness of the brake l...

Page 488: ...ICATIONS 2 SPECIAL TOOLS 2 ON VEHICLE SERVICE 2 1 Steering Angle Check 2 2 Oil Pump Belt Tension Check and Adjustment 2 STEERING WHEEL EVOLUTION IV RS 3 POWER STEERING GEAR LINKAGE 3 POWER STEERING OI...

Page 489: ...Installer bar Pressfitting of gear housing oil seal MB991199 Oil seal installer MB991214 Oil seal protector Installation of rack assembly ON VEHICLE SERVICE 1 STEERING ANGLE CHECK Locate front wheels...

Page 490: ...remove the steering wheel from the boss plate 3 Using the special tool remove the boss plate from the steering column POWER STEERING GEAR LINKAGE For removal installation and inspection procedure foll...

Page 491: ...nd MA 5 Dust cover 6 Clip LA 7 Band 8 Bellows KA 9 Tie rod KA 10 Tab washer JA D Pinion total turning torque adjustment 11 Lock nut AA 12 Rack support cover 13 Support spring 14 Rack support IA 15 End...

Page 492: ...ion Do not close the vent hole in the rack with grease 2 Cover rack serrations with special tool 3 Apply the specified fluid on the special tool seal ring and O ring surfaces Specified fluid MITSUBISH...

Page 493: ...0_ to adjust it for the standard value Caution 1 When adjusting set the standard value at its highest value 2 Assure no ratcheting or catching when operating rack towards the axial direction 3 Be sure...

Page 494: ...ation 1 Power Steering Fluid Supplying 2 Drive Belt Tension Adjusting Refer to GROUP 11 On vehicle Service 1 2 3 4 5 6 7 8 9 10 Unit Nm kgf m 49 5 0 59 69 6 0 7 0 10 12 1 0 1 2 39 4 0 49 5 0 18 1 8 12...

Page 495: ...1 Power Steering Fluid Supplying 2 Drive Belt Tension Adjusting 3 Power Steering Fluid Line Bleeding 1 2 3 4 5 6 7 8 9 10 Unit Nm kgf m 22 2 2 11 22 2 2 52 5 3 24 2 4 12 1 2 18 1 8 Removal steps 1 Dri...

Page 496: ...LER REMOVAL AND INSTALLATION Pre removal and Post installation Operation 1 Power Steering Fluid Draining and Refilling 2 Front Bumper Removal and Installation Refer to GROUP 51 1 2 Unit Nm kgf m 12 1...

Page 497: ...42 1 BODY CONTENTS HOOD 2 FENDER 3 TRUNK LID EVOLUTION V 4 BODY CONSTRUCTION Difference between EVOLUTION IV and V 5 TYPE A PROJECTED DIMENSIONS 7 TYPE B ACTUAL MEASUREMENT DIMENSIONS 11...

Page 498: ...od weatherstrip 4 Hood weatherstrip 5 Hood insulator 6 Bumper 7 Hood support rod 8 Hood outlet garnish weatherstrip 9 Hood outlet garnish 10 Hood inlet garnish upper 11 Hood inlet garnish lower Hood l...

Page 499: ...of different kind Be sure to these special washers Pre removal and Post installation Operation 1 Front Bumper Removal and Installation Refer to GROUP 51 2 Front Turn Signal Lamp Removal and Installat...

Page 500: ...ept for followings INSTALLATION SERVICE POINT TRUNK LID TORSION BAR INSTALLATION 1 Torsion bars are color coded as indicated at their center Torsion bar LH ID color Torsion bar RH ID color White green...

Page 501: ...d wide tread tyres For this reason the configuration and the dimensions of the following body sections are also different SIDE BODY Side Structure 1 The quarter panel has a cut out provided at the inn...

Page 502: ...link bracket rear floor sidemember reinforcement and toe control link bracket have been changed in configuration EVOLUTION V EVOLUTION IV EVOLUTION V EVOLUTION IV Upper link bracket Rear floor sidemem...

Page 503: ...anged as follow Those of the other body sections remain unchanged Unit mm 913 10 1 8 7 9 3 2 950 829 714 173 157 329 329 1 232 810 703 544 940 21 6 1 2 3 7 8 10 9 4 21 6 1 indicates that the dimension...

Page 504: ...ay mounting hole f 30 7 Center bearing mounting bolt end 2 Center of suspension crossmember mounting hole Left f 14 Right f 16 8 Center bearing mounting bolt end 3 Rear portion of front floor sidememb...

Page 505: ...icle indicates that the dimension and the measurement point are the same as those for EVOLUTION IV 21 22 69 65 13 12 11 72 71 70 69 21 22 20 20 12 11 13 65 2 3 2 852 700 810 862 829 597 930 290 270 57...

Page 506: ...of strut insulator f 110 65 Trailing arm mounting position 12 Center of suspension crossmember mounting hole f 15 69 Center of rear shock absorber mounting hole f 68 13 Center of suspension crossmembe...

Page 507: ...indicates that the dimension and the measurement point are the same as those for EVOLUTION IV Unit mm UNDER BODY 10 2 3 7 9 6 6 8 1 8 9 7 3 2 1 21 21 10 1 635 1 028 1 231 1 395 1 287 719 544 933 962...

Page 508: ...per stay mounting hole f 30 7 Center bearing mounting bolt end 2 Center of suspension crossmember mounting hole Left f 14 Right f 16 8 Center bearing mounting bolt end 3 Rear portion of front floor si...

Page 509: ...ON INSTALLATION DIMENSIONS indicates that the dimension and the measurement point are the same as those for EVOLUTION IV Unit mm 2 21 2 13 12 22 20 65 21 20 65 22 12 13 1 210 329 1 186 862 930 597 829...

Page 510: ...ole _ Size shape mm 2 Center of suspension crossmember mounting hole Left f 14 Right f 16 21 Center of suspension crossmember mounting hole f 14 12 Center of suspension crossmember mounting hole f 15...

Page 511: ...OLUTION IV 2 FRONT BUMPER EVOLUTION V 4 REAR BUMPER EVOLUTION V 6 AERO PARTS EVOLUTION IV 7 AERO PARTS EVOLUTION V 8 REAR FENDER GARNISH EVOLUTION V 11 WATER SPRAY EVOLUTION IV 12 INTERCOOLER RADIATOR...

Page 512: ...al Tools Front Bumper EVOLUTION IV 51 2 SPECIAL TOOLS Tool Number Name Use MB990784 Ornament remover Removal of front bumper and rear bumper FRONT BUMPER EVOLUTION IV REMOVAL AND INSTALLATION Front bu...

Page 513: ...vehicles without fog lamps 5 Bumper net side 6 Fog lamp cover vehicles without fog lamps 7 Fog lamp 8 Bumper bolt plate AA 9 Clip 10 Bumper upper reinforcement 11 Grille net 12 Bumper lower reinforce...

Page 514: ...EXTERIOR Front Bumper EVOLUTION V 51 4 FRONT BUMPER EVOLUTION V REMOVAL AND INSTALLATION Front bumper assembly...

Page 515: ...cket 2 mark 3 Bumper center stay 4 Bumper center stay vehicles without fog lamps 5 Air guide panel on driver s seat side 6 Bumper net side 7 Fog lamp plate vehicles without fog lamps 8 Fog lamp cover...

Page 516: ...SASSEMBLY SERVICE POINT AA CLIP REMOVAL 1 Using the special tool raise the pin at the center of the clip 2 Remove the clip REAR BUMPER EVOLUTION V REMOVAL AND INSTALLATION 1 2 Rear bumper removal 1 Re...

Page 517: ...pe SUMITOMO 3M 4211 or equivalent width 5 mm Primer SUMITOMO 3M C100 or equivalent 3 2 5 6 2 5 4 Front air dam removal steps 1 Front air dam center 2 Front air dam 3 Brake duct Side air dam removal AA...

Page 518: ...EXTERIOR Aero Parts EVOLUTION IV 51 8 7 8 Rear spoiler removal steps 7 Rear spoiler 8 High mount stop lamp...

Page 519: ...sert bolt mounting locations Double sided adhesive tape SUMITOMO 3M 4211 or equivalent thickness 1 2 mm Primer SUMITOMO 3M 8107 PP parts primer 4 1 Front air dam removal steps 1 Brake duct AA AA 2 Fro...

Page 520: ...5 Double sided adhesive tape Commercially available product thickness 2 0 mm 5 0 5 Rear spoiler removal steps AA AA 5 Rear spoiler 6 High mount stop lamp undercover 7 High mount stop lamp NOTE The co...

Page 521: ...MO 3M 4213 or equivalent thickness 0 8 mm Primer SUMITOMO 3M 8107 PP parts primer Section A A B B 6 4 4 6 3 Rear door garnish removal steps 1 Clip AA AA 2 Rear door garnish assembly 3 Protector 4 Rear...

Page 522: ...AND INSTALLATION 1 2 3 4 5 6 6 1 Water spray switch Removal steps D Front bumper Refer to P 51 3 2 Washer tank 3 Washer motor 4 Water spray motor 5 Water spray hose 6 Water spray nozzle INSPECTION WA...

Page 523: ...mper Removal and Installation Refer to P 51 4 1 2 3 4 5 6 7 8 9 Unit Nm kgf m 2 5 0 25 2 5 0 25 1 5 5 5 5 5 5 4 4 2 2 1 4 4 5 4 4 4 4 5 3 1 2 1 Clamp 2 Water spray nozzle 3 Water spray nozzle bracket...

Page 524: ...e Tape Tape so that the clip faces toward the front of vehicle Connect to intercooler nozzle RH Connect to intercooler nozzle LH Tape so that the clip faces toward the front of vehicle Connect to radi...

Page 525: ...re used both in front and rear on EVOLUTION V INSTALLATION SERVICE POINT AA MARK INSTALLATION Installation positions The dimension up to the cutout in decal A in fig is the same as the dimension from...

Page 526: ...dy on which the marks are mounted 2 Peel off the release paper from the back side of the mark and affix the mark ensuring the specified dimensions are met Caution 1 Perform the procedure in a dust fre...

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